Body Repair Manual

DEFENDE

Body Repair Manual

NEW RANGE ROVER

This manual covers vehicles from

introduction 1995

01 INTRODUCTION

04 GENERAL SPECIFICATION DATA

60 FRONT SUSPENSION

75 SUPPLEMENTARY RESTRAINT SYSTEM

76 CHASSIS AND BODY

77 PANEL REPAIRS

Published by Rover Technical Communication

P O Box 47, Cowley, OXFORD, OX45NL

 1996 Rover Group Limited

Publication part no. LRL 0085ENG

INTRODUCTION

INFORMATION

INTRODUCTION

This Body Repair Manual is designed to provide the

experienced bodyshop technician with the information

required to carry out efficient and cost effective

repairs.

To assist in the use of this Manual, the section title is

given at the top and the relevant sub-section at the

bottom of each page.

The individual items comprising operations are to be

followed in the sequence in which they appear, see

BODY and SRS sections. Items numbers in the

illustration are referred to in the text. Adjustment and

repair operations include reference to Service Tool

numbers. Each adjustment or repair operation is given

its Service Repair Operation number.

The repair operations cover replacement of the

relevant welded panels and panel assemblies on the

vehicle, see PANEL REPAIRS. The sequence of

operations progresses from the front to the rear of the

vehicle. Each operation details any special points to

observe when replacing a welded panel, together with

cross-references to the relevant trim items to be

removed and replaced for access.

DIMENSIONS

The dimensions quoted are to design engineering

specification with service limits where applicable.

REFERENCES

References to the LH or RH side given in this Manual

are made when viewing the vehicle from the rear.

With the engine and gearbox assembly removed, the

water pump end of the engine is referred to as the

front.

WARNINGS, CAUTIONS and NOTES have the

following meanings:

WARNING: Procedures which must be

followed precisely to avoid the possibility

of injury.

CAUTION: Calls attention to procedures

which must be followed to avoid damage

to components.

NOTE: Gives helpful information.

REPAIRS AND REPLACEMENTS

When replacement parts are required it is essential

that Land Rover parts are used.

Attention is particularly drawn to the following points

concerning repairs and the fitting of replacement parts

and accessories: Safety features embodied in the

vehicle may be impaired if other than Land Rover

parts are fitted. In certain territories, legislation

prohibits the fitting of parts not to the vehicle

manufacturer’s specification. Torque spanner values

given in the Workshop Manual must be strictly

adhered to. Locking devices, where specified, must be

fitted. If the efficiency of a locking device is impaired

during removal it must be replaced with a new one.

Certain fasteners must not be re-used. These

fasteners are specified in the Workshop Manual.

Owners purchasing accessories while travelling

abroad should ensure that the accessory and its fitted

location on the car conform to legal requirements.

The terms of the vehicle Warranty may be invalidated

by the fitting of other than Land Rover recommended

parts.

All Land Rover recommended parts have the full

backing of the vehicle Warranty.

Land Rover dealers are obliged to supply only Land

Rover recommended parts.

INTRODUCTION NEW RANGE ROVER

INFORMATION

SPECIFICATION

Land Rover are constantly seeking to improve the

specification, design and production of their vehicles

and alterations take place accordingly. While every

effort has been made to ensure the accuracy of this

Manual, it should not be regarded as an infallible

guide to current specifications of any particular

vehicle.

This Manual does not constitute an offer for sale of

any particular vehicle. Land Rover dealers are not

agents of Land Rover and have no authority to bind

the manufacturer by any expressed or implied

undertaking or representation.

INTRODUCTION

BODY DIMENSIONS

ALIGNMENT JIG DIMENSIONS

1. 1190mm (46.8in.)

2. 1709mm (67.3in.)

3. 2527mm (99.6in.)

4. 4173mm (164.4in.)

5. 717mm (28.3in.)

6. 982.5mm (38.7in.)

7. 1328mm (52.3in.)

8. 1697mm (66.9in.)

9. 3159mm (124.5in.)

10. 1340mm (52.8in.)

11. 1302mm (51.3in.)

12. 665mm (26.2in.)

13. 1400mm (55.2in.)

14. 2364mm (93.1in.)

15. 1803mm (71.0in.)

A = No. 1 body mount RH and LH

B = Front spring seat RH and LH

C = No. 2 body mount RH and LH

D = Front crossmember piercing RH and LH

E = Front radius arm mounting bracket RH and LH

F = No. 3 body mount RH and LH

G = Rear composite link mounting bracket RH and

H = No. 5 body mount RH and LH

All dimensions taken at centre line of set screw or set screw hole.

INTRODUCTION NEW RANGE ROVER

BODY DIMENSIONS

Straightening

Whenever possible, structural members should be

cold straightened under tension. Do not attempt to

straighten with a single pull, but rework the damaged

area using a series of pulls, releasing tension between

each stage and using the opportunity to check

alignment.

Body jig

Unless damage is limited to cosmetic panels, all repair

work to body members must be carried out on a body

jig, to ensure that impact damage has not spread into

more remote parts of the body structure. Mounting on

a jig will also ensure that the straightening and panel

replacement procedures do not cause further

distortion. If original dimensions cannot be

satisfactorily restored by these methods, damaged

structural members should be replaced. Damaged

areas should be cut away using a high speed saw,

NOT an oxy-acetylene torch.

As a rule, body dimensions are symmetrical about the

centre line. A good initial check for distortion is

therefore to measure diagonally and to investigate

apparent differences in dimensions.

Inspection

Every accident produces individual differences in

damage. Each repair is influenced by the extent of the

damage and by the facilities and equipment available

for its rectification.

Most accident damage can be visually inspected and

the approximate extent of the damage assessed.

Sometimes deformation will extend beyond the area

of direct damage, and the severity of this must be

accurately established so that steps may be taken to

restore critical body components to their original

dimensions.

An initial check of critical dimensions can be carried

out by means of drop checks or (preferably) trammels.

Gauges are available which will check accurately for

body twist. Where repairs necessitate renewal of a

critical body component it is recommended that a

body jig is used.

GENERAL SPECIFICATION DATA

INFORMATION

VEHICLE IDENTIFICATION NUMBER (VIN)

An adhesive label containing the Vehicle Identification

Number and the recommended maximum vehicle

weights is located on the left hand side of the bonnet

locking platform.

The number is also stamped on the right side of the

chassis forward of the spring mounting turret.

Key to Vehicle Identification Number Plate

A. VIN (17 digits)

B. Maximum permitted laden weight for vehicle

C. Maximum vehicle and trailer weight

D. Maximum road weight-front axle

E. Maximum road weight-rear axle

In addition the VIN is stamped on a plate which is

visible through the left side of the windscreen.

Federal (USA) vehicle identification number

An adhesive label containing the Vehicle Identification

Number, date of manufacture and gross axle weight

ratings is fixed to the lock face of the front left hand

door. The information includes wheel and tyre sizes

and tyre pressures at gross axle weight ratings.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

INFORMATION

LOCATION OF IDENTIFICATION NUMBERS

Engine serial number - V8 engine

Stamped on a cast pad on the cylinder block, between

numbers 3 and 5 cylinders.

NOTE: The engine compression ratio is

stamped above the serial number.

Engine serial number - BMW Diesel engine

Stamped on the LH side of the cylinder block above

the sump.

Main gearbox R380 - 5 speed

Stamped on a cast pad on the bottom right hand side

of the gearbox.

Automatic gearbox ZF4HP22

Stamped on a plate riveted to the bottom left hand

side of the gearbox casing.

GENERAL SPECIFICATION DATA

INFORMATION

Transfer gearbox-Borg Warner

Stamped on a plate attached to the gearbox casing,

between filler/level and drain plug.

Front and rear axle

Stamped on the left hand axle tubes.

Vehicle identification number (VIN)

Made up of 17 digits, these numbers are used to

identify manufacturer, model range, specification,

body type, engine, transmission/steering, model year,

plant and build sequence number and serve to identify

the vehicle.

This example shows the sequence:

European code

SALLPAMJ7MA

S Europe

AL UK

LP Range Rover

A European Spec.

M 4 Door Station Wagon

J 4.6 Litre Fuel Injection

7 Manual right steering

M 1995 Model Year

A Solihull

Federal (USA) code

SALPV1242SA

S Europe

AL UK

P Range Rover

V North America Spec.

1 4 Door Station Wagon

2 4.0 Litre fuel injection

4 Automatic, Left Hand Steering

2 Check Digit

S 1995 Model Year

A Solihull

GENERAL SPECIFICATION DATA NEW RANGE ROVER

INFORMATION

SAFETY INSTRUCTIONS

Jacking

The recommended jacking points are given in

LIFTING AND TOWING.Always ensure that any lifting

apparatus has adequate load and safety capacity for

the weight to be lifted. Ensure the vehicle is standing

on level ground prior to lifting or jacking. Apply the

handbrake and chock the wheels.

Never rely on a jack as the sole means of support

when working beneath the vehicle. Use additional

safety supports beneath the vehicle.

Do not leave tools, lifting equipment, spilt oil, etc.

around or on the work bench area.

Precautions against damage

Always fit wing and seat covers before commencing

work. Avoid spilling brake fluid or battery acid on

paintwork. Wash off with water immediately if this

occurs.

Disconnect the battery earth lead before starting work.

See ELECTRICAL PRECAUTIONS.

Always use the recommended service tool or a

satisfactory equivalent where specified.

Protect exposed bearing and sealing surfaces and

screw threads from damage.

Brake Hydraulics

WARNING: It is imperative that the correct

brake fittings are used and that threads of

components are compatible.

Always use two spanners when slackening or

tightening brake pipe or hose connections. Ensure

that hoses run in a natural curve and are not kinked or

twisted. Fit brake pipes securely in their retaining clips

and ensure that the pipe run cannot contact a

potential chafing point.

Containers used for hydraulic fluid must be kept

absolutely clean. Do not store hydraulic fluid in an

unsealed container; it will absorb water and in this

condition will be dangerous to use. Do not allow

hydraulic fluid to be contaminated with mineral oil, or

use a container which has previously contained

mineral oil. Do not re-use fluid from the system.

Always use clean brake fluid or a recommended

alternative to clean hydraulic components. Fit a

blanking cap to an hydraulic union and a plug to its

socket after removal to prevent the ingress of dirt.

Absolute cleanliness must be observed with hydraulic

components.

Engine coolant caps and plugs

Extreme care is necessary when removing engine

coolant caps and plugs when the engine is hot and

especially if it is overheated. To avoid the possibility of

scalding allow the engine to cool before attempting

coolant cap or plug removal.

Cleaning components

Always use the recommended cleaning agent or

equivalent.

Do not use degreasing equipment for components

containing items which could be damaged by the use

of its process. Whenever possible clean components

and the area surounding them before removal. Always

observe scrupulous cleanliness when cleaning

dismantled components.

GENERAL SPECIFICATION DATA

INFORMATION

FUEL HANDLING PRECAUTIONS

The following information provides basic precautions

which must be observed if fuel is to be handled safely.

It also outlines the other areas of risk which must not

be ignored.

This information is issued for basic guidance only, and

in any case of doubt, appropriate enquiries should be

made of your local Fire Officer or Fire Department.

Fuel vapor is highly flammable and in confined spaces

is also very explosive and toxic.

When fuel evaporates it produces 150 times its own

volume in vapor, which when diluted with air becomes

a readily ignitable mixture. The vapor is heavier than

air and will always fall to the lowest level. It can readily

be distributed throughout a workshop by air current,

consequently, even a small spillage of fuel is very

dangerous.

Always have a fire extinguisher containing FOAM CO

GAS, or POWDER close at hand when handling fuel,

or when dismantling fuel systems and in areas where

fuel containers are stored.

WARNING: lt is imperative that the battery

is not disconnected during fuel system

repairs as arcing at the battery terminal

could ignite fuel vapour in the atmosphere.

Always disconnect the vehicle battery BEFORE

carrying out work on the fuel system.

Whenever fuel is being handled, transferred or

stored, or when fuel systems are being dismantled

all forms of ignition must be extinguished or

removed, any leadlamps used must be flame proof

and kept clear of spillage.

No one should be permitted to repair components

associated with fuel without first having had fuel

system training.

Hot fuel handling precautions

WARNING: Before commencing any

operation requiring fuel to be drained from

the fuel tank, the following procedure must

be adhered to:

1. Allow sufficient time for the fuel to cool, thus

avoiding contact with hot fuels.

2. Vent the system by removing the fuel filler cap in

a well ventilated area. Refit the filler cap until the

commencement of fuel drainage.

Fuel transfer

WARNING: Fuel must not be extracted or

drained from any vehicle while it is

standing over a pit.

The transfer of fuel from the vehicle fuel tank must be

carried out in a well ventilated area. An approved

transfer tank must be used according to the transfer

tank manufacturer’s instructions and local regulations,

including attention to grounding of tanks.

Fuel tank removal

A FUEL VAPOUR warning label must be attached to

the fuel tank upon removal from the vehicle.

Fuel tank repair

Under no circumstances should a repair to any tank

be attempted.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

INFORMATION

ELECTRICAL PRECAUTIONS

General

The following guidelines are intended to ensure the

safety of the operator whilst preventing damage to the

electrical and electronic components fitted to the

vehicle. Where necessary specific precautions are

detailed in the relevant sections of this Manual which

should be referred to prior to commencing repair

operations.

Equipment - Prior to commencing any test procedure

on the vehicle ensure that the relevant test equipment

is working correctly and any harness or connectors

are in good condition. This particularly applies to

mains lead and plugs.

WARNING: Before commencing work on

an ignition system all high tension

terminals, adaptors and diagnostic

equipment for testing should be inspected to

ensure that they are adequately insulated and

shielded to prevent accidental personal contacts

and minimise the risk of shock. Wearers of

surgically implanted pacemaker devices should

not be in close proximity to ignition circuits or

diagnostic equipment.

Polarity - Never reverse connect the vehicle battery

and always observe the correct polarity when

connecting test equipment.

High Voltage Circuits - Whenever disconnecting live ht

circuits always use insulated pliers and never allow

the open end of the ht lead to come into contact with

other components, particularly ECU’s. Exercise

caution when measuring the voltage on the coil

terminals while the engine is running, as high voltage

spikes can occur on these terminals.

Connectors and Harness - The engine compartment

of a vehicle is a particularly hostile environment for

electrical components and connectors. Always ensure

these items are dry and oil free before disconnecting

and connecting test equipment. Never force

connectors apart either by using tools or by pulling on

the wiring harness. Always ensure locking tabs are

disengaged before removal and not orientation to

enable correct reconnection. Ensure that any

protective covers and substances are replaced if

disturbed.

Having confirmed a component to be faulty, switch off

the ignition and disconnect the battery. Remove the

component and support the disconnected harness.

When replacing the component keep oily hands away

from electrical connection areas and push connectors

home until any locking tabs fully engage.

Battery disconnecting

Before disconnecting the battery, switch off all

electrical equipment. If the radio is to be serviced,

ensure the security code has been deactivated.

CAUTION: To prevent damage to electrical

components ALWAYS disconnect the

battery when working on the vehicle

electrical system. The earth lead must be

disconnected first and reconnected last. Always

ensure that battery leads are routed correctly and

are not close to any potential chafing points.

Battery charging

Recharge the battery out of the vehicle and keep the

top well ventilated. While being charged or

discharged, and for approximately fifteen minutes

aferwards, batteries emit hydrogen gas. This gas is

inflammable.

Always ensure any battery charging is well ventilated

and that every precaution is taken to avoid naked

flames and sparks.

GENERAL SPECIFICATION DATA

INFORMATION

Jump starting

WARNING: Hydrogen and oxygen gases

are produced during normal battery

operation. This gas mixture can explode if

flames, sparks or lighted tobacco are brought

near battery. When charging or using a battery in

an enclosed space, always provide ventilation and

shield your eyes.

Keep out of reach of children. Batteries contain

sulphuric acid. Avoid contact with skin, eyes, or

clothing. Also, shield eyes when working near

battery to protect against possible splashing of

acid solution. In case of acid contact with skin,

eyes, or clothing, flush immediately with water for

a minimum of fifteen minutes. If acid is swallowed,

drink large quantities of milk or water, followed by

milk of magnesia, a beaten egg, or vegetable oil.

SEEK MEDICAL AID IMMEDIATELY.

To Jump Start - Negative Ground Battery

WARNING: To avoid any possibility of

injury use particular care when connecting

a booster battery to a discharged battery.

1. Position vehicles so that jump leads will reach,

ensuring that vehicles DO NOT TOUCH,

alternatively a fully charged slave battery may be

positioned on floor adjacent to vehicle.

2. Ensuring that ignition and all electrical

accessories are switched off, that parking brake

is applied and neutral is selected on a manual

gearbox, with an automatic gearbox select

neutral (N) or park (P) and then connect the

jump leads as follows;

A. Connect one end of first jumper cable to positive

(+) terminal of booster battery.

B. Connect other end of first jumper cable to

positive (+) terminal of discharged battery.

C. Connect one end of second jumper cable to

negative terminal of booster battery.

D. Connect other end of second jumper cable to a

good earth point on the engine, NOT TO

NEGATIVE TERMINAL OF DISCHARGED

BATTERY. Keep jumper lead away from moving

parts, pulleys, drive belts and fan blade

assembly.

WARNING: Making final cable connection

could cause an electrical arc which if

made near battery could cause an

explosion.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

INFORMATION

3. If booster battery is installed in another vehicle,

start engine and allow to idle.

4. Start engine of vehicle with discharged battery,

following starting procedure in Owners’ Manual.

CAUTION: If vehicle fails to start within a

maximum time of 12 seconds, switch

ignition off and investigate cause. Failing

to follow this instruction could result in

irrepairable damage to catalysts.

5. Remove negative (-) jumper cable from the

engine and then terminal of booster battery.

6. Remove positive (+) jumper cable from positive

terminals of booster battery and discharged

battery.

Disciplines

Switch off ignition prior to making any connection or

disconnection in the system as electrical surge

caused by disconnecting ’live’ connections can

damage electrical components.

Ensure hands and work surfaces are clean and free of

grease, swarf, etc. as grease collects dirt which can

cause tracking or high-resistance contacts.

When handling printed circuit boards, treat them as

you would a disc - hold by the edges only; note that

some electronic components are susceptible to body

static.

Connectors should never be subjected to forced

removal or refit, especially inter-board connectors, as

damaged contacts will cause short circuit and

open-circuit conditions.

Prior to commencing test, and periodically during test,

touch a good earth (i.e. cigar lighter socket) to

discharge body static as some electronic components

are vulnerable to static electricity.

Grease for electrical connectors

All underbonnet and underbonnet connectors are

protected against corrosion by the application of a

special grease on production. Should connectors be

disturbed in service, repaired or replaced, a grease of

this type (available in 150gm tubes under Part No.

BAU 5811) should again be applied.

NOTE: The use of other greases must be

avoided as they can migrate into relays,

switches etc., contaminating the contacts

and leading to intermittent operation or failure.

GENERAL SPECIFICATION DATA

INFORMATION

BODY REPAIRS

Body shells are of welded construction and bolted to

the chassis frame. Front and rear sections of the shell

are designed as ’energy absorbing’ zones. This

means they are designed to deform progressively

when subjected to impact in order to minimise the

likelihood of injury to vehicle occupants.

It is essential that design dimensions and strength are

restored in accident rectification. It is important that

neither structural weakness nor excessive local

stiffness are introduced into the vehicle during body or

chassis repair.

Repairs usually involve a combination of operations

ranging from straightening procedures to renewal of

either individual panels or panel assemblies. The

repairer will determine the repair method and this

decision will take into account a balance of economics

between labour and material costs and the availability

of repair facilities in both equipment and skills. It may

also involve considerations of vehicles down-time,

replacement vehicle availability and repair turn-around

time.

It is expected that a repairer will select the best and

most economic repair method possible, making use of

the facilities available. The instructions given are

intended to assist a skilled body repairer by expanding

approved procedures for panel replacement with the

objective of restoring the vehicle to a safe running

condition and effecting a repair which is visually

acceptable and which, even to the experienced eye,

does not advertise the fact that it has been damaged.

This does not necessarily mean that the repaired

vehicle will be identical in all respects with original

factory build. Repair facilities cannot always duplicate

methods of construction used during production.

Operations covered in this Manual do not include

reference to testing the vehicle after repair. It is

essential that work is inspected and suspension

geometry checked after completion and if necessary a

road test of the vehicle is carried out, particularly

where safety related items are concerned.

Where major units have been disconnected or

removed, it is necessary to ensure that fluid levels are

checked and topped up when necessary. It is also

necessary to ensure that the repaired vehicle is in a

roadworthy condition in respect of tyre pressures,

lights, washer fluid etc.

Body repairs often involve the removal of mechanical

and electrical units as well as associated wiring. See

BODY and SRS sections.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

INFORMATION

Taking into consideration the differences in body

styles, steering and suspension systems as well as

engine and suspension layouts, the location of the

following components as applicable to a particular

vehicle is critical:

• Front suspension upper damper

mountings.

• Front suspension or sub frame mountings.

• Engine mounting on RH and LH chassis

longitudinals.

• Rear suspension upper damper mountings.

• Rear suspension mountings or lower

pivots.

• Steering rack mountings.

Additional points which can be used to check

alignment and assembly are:

• Inner holes in crossmember - side - main

floor.

• Holes in front longitudinals.

• Holes in extension - side member - front.

• Holes in rear longitudinals.

• Holes in rear lower panels or extension

rear floor.

• Fuel tank mountings.

Apertures for windscreen, backlight, bonnet and doors

can best be checked by offering up an undamaged

component as a gauge.

GENERAL SPECIFICATION DATA

INFORMATION

JACKING

The following instructions must be carried out before

raising the vehicle off the ground.

1. Use a solid level ground surface.

2. Apply parking brake.

3. Select ’P’ or 1st gear in main gearbox.

4. Select Low range in transfer gearbox.

CAUTION: To avoid damage occurring to

the under body components of the vehicle

the following jacking procedures must be

adhered to.

DO NOT POSITION JACKS OR AXLE STANDS

UNDER THE FOLLOWING COMPONENTS.

Body structure Air suspension pipes

Bumpers Fuel lines

Brake lines Front radius arms

Panhard rod Steering linkage

Rear Trailing links Fuel tank

Engine sump Gearbox bell housing

CAUTION: If supporting vehicle by the

front crossmember, the safety stands

must be postioned carefully to avoid

damage to air suspension pipes.

Vehicle jack

The jack provided with the vehicle is only intended to

be used in an emergency, for changing a tyre. Do

NOT use the jack for any other purpose. Refer to

Owner’s Manual for vehicle jack location points and

procedure. Never work under a vehicle supported by

the vehicle jack.

Hydraulic jack

A hydraulic jack with a minimum 1500 kg, 3,300 lbs

load capacity must be used.

CAUTION: Do not commence work on the

underside of the vehicle until suitable axle

stands have been positioned under the

axle.

Raise the front of the vehicle

1. Position cup of hydraulic arm under differential

casing.

NOTE: The differential casing is not

central to the axle. Care should be taken

when raising the front road wheels off the

ground as the rear axle has less sway stiffness.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

INFORMATION

2. Raise front road wheels to enable an axle stand

to be installed under left hand axle tube.

3. Position an axle stand under right hand axle

tube, carefully lower jack until axle sits securely

on both axle stands, remove trolley jack.

4. Before commencing work on underside of

vehicle re-check security of vehicle on stands.

5. Reverse procedure when removing vehicle from

stands.

Raise rear of vehicle

1. Position cup of hydraulic arm under differential

casing.

2. Raise vehicle to enable axle stands to be

installed under left and right hand axle tubes.

3. Lower jack until axle sits securely on axle

stands, remove trolley jack.

4. Before commencing work on underside of

vehicle re-check security of vehicle on stands.

5. Reverse procedure when removing vehicle from

stands.

GENERAL SPECIFICATION DATA

INFORMATION

HYDRAULIC VEHICLE RAMP (FOUR POST)

Use only a ’drive on’ type ramp which supports vehicle

by its own road wheels. If a ’wheel-free’ condition is

required, use a ’drive on’ ramp incorporating a

’wheel-free’ system that supports under axle casings.

Alternatively, place vehicle on a firm, flat floor and

support on axle stands.

TWO POST VEHICLE RAMPS

The manufacturer of RANGE ROVER VEHICLES

DOES NOT recommend using ’Two Post’ ramps

that employ four adjustable support arms. These

are NOT considered safe for Range Rover

vehicles.

If vehicle is installed on a Two Post ramp

responsibility for safety of vehicle and personnel

performing service operations is in the hands of

the Service Provider.

DYNAMOMETER TESTING - VEHICLES WITH

ANTI-LOCK BRAKES (ABS)

WARNING: Do not attempt to test ABS

function on a dynamometer

Four wheel dynamometers

NOTE: Before testing a vehicle on a four

wheel dynamometer disconnect the valve

relay.

See Electrical Trouble Shooting

Manual.

The ABS function will not work, the ABS warning

light will illuminate. Normal braking will be

available.

Provided that front and rear rollers are rotating at

identical speeds and that normal workshop safety

standards are applied, there is no speed restriction

during testing except any that may apply to the tyres.

Two wheel dynamometers

IMPORTANT: Use a four wheel dynamometer for

brake testing if possible.

NOTE: ABS will not function on a two

wheel dynamometer. The ABS light will

illuminate during testing. Normal braking

will be available.

If brake testing on a single rig is necessary it must be

carried out with propeller shaft to the rear axle

removed, AND neutral selected in BOTH main and

transfer boxes.

If checking engine performance, the transfer box must

be in high range and drive shaft to stationary axle

removed.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

INFORMATION

EMERGENCY TOWING

CAUTION: The New Range Rover has

permanent four-wheel drive. The following

instructions must be adhered to when

towing:-

Towing the vehicle on four wheels

If it is necessary to recover the vehicle by towing on

all four wheels, ’Transfer neutral’ MUST be selected.

1. With the starter key removed, insert a fuse of 5

amps or more in fuse position ’11’ in the RH seat

fuse box.

2. Turn the starter switch to position ’2’; the transfer

box will now automatically select neutral.

3. Wait until the message centre displays

’TRANSFER NEUTRAL’ and then turn the

starter switch off, position ’0’.

4. Turn the starter switch to position ’1’ to unlock

the steering and leave in this position while the

vehicle is being towed.

5. Secure tow rope to the front towing eye.

6. Release the parking brake.

CAUTION: The brake servo and power

assisted steering system will not be

functional without the engine running.

Heavier pedal pressure will be required to apply

the brakes, the steering system will require

greater effort to turn the front wheels.

The vehicle tow connection should be used only

in normal road conditions.

CAUTION: DO NOT remove the starter key

or turn the switch to position ’0’ when the

vehicle is in motion.

7. To reactivate the transfer box after towing, turn

the starter switch off to position ’0’ and remove

the fuse from position ’11’. On automatic

vehicles the transfer box will automatically

engage the Low or High gear range.

8. On manual vehicles, first press the range

change switch. The transfer box will then engage

the Low or High gear range.

Suspended tow by breakdown vehicle

CAUTION: To prevent vehicle damage,

front or rear propeller shaft MUST be

removed, dependant upon which axle is

being trailed.

9. To facilitate reassembly, first mark the propeller

shaft drive flanges at transfer box and axle.

10. Remove propeller shaft fixings and lift shaft from

vehicle.

11. If the front axle is to be trailed turn ignition key to

position ’1’ to release the steering lock.

CAUTION: If the rear axle is to be raised,

the steering wheel and/or linkage MUST be

secured in a straight ahead position. DO

NOT use the steering lock for this purpose.

GENERAL SPECIFICATION DATA

INFORMATION

TRANSPORTING THE VEHICLE BY TRAILER

If the vehicle should require transporting on a trailer or

the back of a lorry, the air suspension must be set to

’ACCESS’ before being lashed.

See FRONT

SUSPENSION, Description and operation.

Lashing eyes are provided on the front and rear

chassis cross members to facilitate the securing of the

vehicle, as shown.

CAUTION: DO NOT secure lashing hooks

or trailer fixings to any other part of the

vehicle.

CAUTION: If the air suspension cannot be

set to the ’ACCESS’ position, then the

vehicle must be lashed by its wheels and

not the lashing eyes.

Install vehicle on the trailer and apply park brake.

Select neutral in main gearbox; this will prevent

damage to the parking pawl of the automatic gearbox.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

INFORMATION

VEHICLE DIMENSIONS

mm inches

Overall length 4713................................................................... 185.6

with Europe/UK towbar 4804........................................... 189.1

Overall width 1889.................................................................... 74.4

Overall height at standard profile 1817.5..................................... 71.6

Wheelbase 2745....................................................................... 108.1

Track:

Front 1540........................................................................ 60.6

Rear 1530........................................................................ 60.2

Turning circle between kerbs 1189 mm (39 ft)...........................................

STEERING

Power steering box

Make/type ZF type 8055, recirculating ball steering gear........................................................................

Steering wheel turns, lock-to-lock 3.2....................................

Steering pump

Make/type:

V8 engine ZF type 7691, vane type................................................................

Diesel engine ZF type7681, vane type..........................................................

Steering geometry

Steering wheel diameter 406.4mm (16 in.)..................................................

Toe-out measurement 0.6 to 1.80mm (0.02 - 0.07 in.)......................................................

Toe-out included angle 0˚ 5’ to 0˚ 15’.....................................................

Camber angle 0˚.................................................................. NOTE:

Castor angle 4˚..................................................................... Check at

Swivel pin inclination static 8˚............................................... kerbweight

GENERAL SPECIFICATION DATA

INFORMATION

VEHICLE WEIGHTS AND PAYLOAD

When loading a vehicle to its maximum (Gross Vehicle Weight), consideration must be taken of the vehicle kerb

weight and the distribution of the payload to ensure that axle loadings do not exceed the permitted maximum

values. It is the customer’s responsibility to limit the vehicle’s payload in an appropriate manner such that neither

maximum axle loads nor Gross Vehicle Weight are exceeded.

GROSS VEHICLE WEIGHT

Petrol Models Diesel Models

Front Axle 1320 kg (2910 lb).............................. 1320 kg (2910 lb).............

Rear Axle 1840 kg (4056 lb).............................. 1840 kg (4056 lb).............

Total 2780 kg (6129 lb)...................................... 2780 kg (6129 lb).............

Maximum Payload 603 kg (1329 lb)................. 596 kg (1314 lb)...............

EEC KERB WEIGHT AND DISTRIBUTION

4.0 Litre Manual 4.0 Litre Automatic 4.6 Litre Automatic

EEC Kerb Weight 2090 kg (4607 lb).................. 2100 kg (4629 lb)............. 2220 kg (4894 lb).............

Front Axle 1095 kg (2414 lb).............................. 1100 kg (2425 lb)............. 1165 kg (2568 lb).............

Rear Axle 995 kg (2193 lb).............................. 1000 kg (2204 lb)............... 1055 kg (2325 lb).............

2.5 Diesel Manual 2.5 Diesel Automatic

EEC Kerb Weight 2115 kg (4662 lb).................. 2130 kg (4695 lb).............

Front Axle 1110 kg (2447 lb).............................. 1120 kg (2469 lb).............

Rear Axle 1005 kg (2215 lb).............................. 1010 kg (2226 lb).............

NOTE: EEC KERB WEIGHT is the minimum vehicle specification plus full fuel tank and 75 kg

(165lb) driver.

NOTE: GROSS VEHICLE WEIGHT is the maximum all-up weight of the vehicle including driver,

passengers, and equipment. This figure is liable to vary according to legal requirements in certain

countries.

NOTE: MAXIMUM ROOF RACK LOAD (including weight of rack) 75 kg (165 lb) must be included in

total vehicle weight.

GENERAL SPECIFICATION DATA

BODY DIMENSIONS

ALIGNMENT JIG DIMENSIONS

1. 1190mm (46.8in.)

2. 1709mm (67.3in.)

3. 2527mm (99.6in.)

4. 4173mm (164.4in.)

5. 717mm (28.3in.)

6. 982.5mm (38.7in.)

7. 1328mm (52.3in.)

8. 1697mm (66.9in.)

9. 3159mm (124.5in.)

10. 1340mm (52.8in.)

11. 1302mm (51.3in.)

12. 665mm (26.2in.)

13. 1400mm (55.2in.)

14. 2364mm (93.1in.)

15. 1803mm (71.0in.)

A = No. 1 body mount RH and LH

B = Front spring seat RH and LH

C = No. 2 body mount RH and LH

D = Front crossmember piercing RH and LH

E = Front radius arm mounting bracket RH and LH

F = No. 3 body mount RH and LH

G = Rear composite link mounting bracket RH and

H = No. 5 body mount RH and LH

All dimensions taken at centre line of set screw or set screw hole.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

BODY DIMENSIONS

Straightening

Whenever possible, structural members should be

cold straightened under tension. Do not attempt to

straighten with a single pull, but rework the damaged

area using a series of pulls, releasing tension between

each stage and using the opportunity to check

alignment.

Body jig

Unless damage is limited to cosmetic panels, all repair

work to body members must be carried out on a body

jig, to ensure that impact damage has not spread into

more remote parts of the body structure. Mounting on

a jig will also ensure that the straightening and panel

replacement procedures do not cause further

distortion. If original dimensions cannot be

satisfactorily restored by these methods, damaged

structural members should be replaced. Damaged

areas should be cut away using a high speed saw,

NOT an oxy-acetylene torch.

As a rule, body dimensions are symmetrical about the

centre line. A good initial check for distortion is

therefore to measure diagonally and to investigate

apparent differences in dimensions.

Inspection

Every accident produces individual differences in

damage. Each repair is influenced by the extent of the

damage and by the facilities and equipment available

for its rectification.

Most accident damage can be visually inspected and

the approximate extent of the damage assessed.

Sometimes deformation will extend beyond the area

of direct damage, and the severity of this must be

accurately established so that steps may be taken to

restore critical body components to their original

dimensions.

An initial check of critical dimensions can be carried

out by means of drop checks or (preferably) trammels.

Gauges are available which will check accurately for

body twist. Where repairs necessitate renewal of a

critical body component it is recommended that a

body jig is used.

GENERAL SPECIFICATION DATA

COMPONENT LOCATION

ELECTRONIC CONTROL UNITS

1. Engine control module (ECM) (at RH of engine

bay)

2. ABS ECU (behind access plate at LH of

dashboard)

3. Cruise control ECU (behind fascia closing panel)

4. Diagnostic control unit (on centre tunnel)

5. Electronic suspension ECU (beneath LH front

seat)

6. Body electrical control module (BeCM) (beneath

RH front seat)

The electronic control units fitted to Land Rover

vehicles make it advisable to follow suitable

precautions prior to carrying out welding repair

operations. Harsh conditions of heat and vibration

may be generated during these operations which

could cause damage to the units. See ELECTRICAL

PRECAUTIONS section.

In particular, it is essential to follow the appropriate

precautions when disconnecting or removing the SRS

diagnostic unit. See SUPPLEMENTARY RESTRAINT

SYSTEM, Precautions section.

GENERAL SPECIFICATION DATA

SEALING AND CORROSION PROTECTION

APPROVED MATERIALS

MATERIAL MANUFACTURER

3M:

Bodygard (08158, 08159)

Weld Thru’ Sealer (08625)

Drip-Chek Clear (08401)

Drip-Chek Heavy (08531)

Flexseal Polyurethane Seam Sealer (08684, 08689, 08694)

Polyurethane Sealer (sachet) (08703, 08783, 08788)

Super Seam Sealer (08537)

Sprayable Sealer (08800, 08823)

Bolted Panel Sealer (08572)

Body Caulking (08568)

Windscreen Sealer (08509)

Gurit-Essex:

Betafill Clinch and Brushable Sealer (Black) (10215)

Betafill Clinch and Brushable Sealer (Grey) (10211)

Betafill Clinch and Brushable Sealer (White) (10220)

Clinch Joint and Underbody Coating (Grey) (10101)

Clinch Joint and Underbody Coating (Beige) (10707)

SEALERS Kent Industries:

Leak-Chek Clear Putty (10075)

PPG:

Polyurethane Seam Sealer (6500)

Polyurethane Seam Sealer (92)

Terostat Preformed Strip (V11)

Terolan Light Seam Sealer

Teroson:

Terolan Special Brushable Seam Sealer

Terostat 1K PU Seam Sealer (SE20)

Terostat Sprayable Seam Sealer (9320)

Unipart:

Promatch Sealing Compound (UBS605, UBS606, UBS607)

Promatch Bolted Panel Sealer (UBS111)

Wurth:

Sealing Compound (890100, 890101, 890102, 890103, 890104,

890105, 890106)

Astrolan Engine Bay Wax & Cosmetic Wax (DA3241/DA3243)

Weld Thru’ Coating (05913)

GENERAL SPECIFICATION DATA NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

Approved materials (continued)

MATERIAL MANUFACTURER

3M:

Automotive Structural Adhesive (08120)

Aerosol Auto Adhesive (Trim) (08080)

ADHESIVES Spray 80 Adhesive (08090)

Ciba-Geigy:

Structural Two-Part Epoxy (XB5106/XB5107)

3M:

Spray Schutz (08877)

Body Schutz (08861)

Stone Chip Coating (Textured) (08868, 08878, 08879)

Stone Chip Coating (Smooth) (08158, 08160, 08886)

Croda:

Crodapol Brushable Underbody Sealer (PV75)

UNDERBODY COATINGS Underbody Wax (PW61)

Dinol:

Tectacote Underbody Wax (205)

Teroson:

Terotex Underseal CP02 (9320)

Unipart:

Promatch Underbody Schutz (UBS410)

Promatch Underbody Wax (PW61)

3M:

Inner Cavity Wax (Transparent) (08909, 08919, 08929)

Inner Cavity Wax (Amber) (08901, 08911, 08921)

Dinol:

Engine Bay & Cosmetic Wax/Lacquer (PW197)

WAX COATINGS Cavity Wax (PW57)

Engine Bay Cosmetic Wax/Lacquer (4010)

Unipart:

Promatch Cavity Wax (UBS508)

GENERAL SPECIFICATION DATA

SEALING AND CORROSION PROTECTION

Approved materials (continued)

MATERIAL MANUFACTURER

3M:

Zinc Spray (09113)

WELD-THROUGH PRIMERS ICI:

Zinc Rich Primer (P-565 634)

3M:

Flexible Parts Repair Material (05900)

Cleaner and Wax Remover (1 litre) (08984)

Waterproof Cloth Tape (Y387/YS3998)

GENERAL MATERIALS Teroson:

Sprayable Aerosol, Water Shedder Repair

Unipart:

Waterproof Tape (GWS121)

Urethane Butyl Tape (BHM605)

GENERAL SPECIFICATION DATA NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

MATERIALS APPLICATIONS

Joint Types:

1. Between bolted panels

2. Between bolted panel edges

3. Between spot welded panels

4. Between spot welded panel edges

5. Between bonded panels

6. Between bonded panel edges

7. Clinch joints (type a)

8. Clinch joints (type b)

9. Clinch joints (type c)

10. Gaps between panels (type a)

11. Gaps between panels (type b)

GENERAL SPECIFICATION DATA

SEALING AND CORROSION PROTECTION

Materials applications (continued)

MANUFACTURER MATERIAL/JOINT TYPE

ICI P565 634 Zinc rich primer. Between bolted and spot welded panels,

3M 09113 clinch joints (type a). Brush or spray application.

Teroson Terostat V11 Preformed strip. Between bolted panels. Hand application.

Kent Industries 10075

3M 08401

3M 08572

3M 08684

3M 08689

3M 08694

3M 08703 Seam sealer. Between bolted panel edges. Applicator gun/by hand.

3M 08783

3M 08788

PPG Polyurethane 6500

Teroson 92

Terolan Light

Terostat 1K PU

Terostat 9320

Unipart UBS 605/6/7

Wurth 890100/1/2/3/4/5/6

Ciba-Geigy XBS106/7 Structural adhesive. Between spot welded and bonded panels,

3M 08120 clinch joints (type a). Applicator gun, caulking gun.

3M 08625 Seam sealer. Between spot welded panels. Applicator gun.

Kent Industries 10075

3M 08401

3M 08684

PPG 6500

Teroson 92 Seam sealer light. Between spot welded panel edges.

Terolan Light Hand applicator gun.

Terostat 9320

Terostat 1K PU

Unipart UBS605/6/7

Wurth 890100/1/2/3/4/5/6

GENERAL SPECIFICATION DATA NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

Materials applications (continued)

MANUFACTURER MATERIAL/JOINT TYPE

Ciba-Geigy XBS106/7 Structural adhesive. Between bonded panels. Caulking gun.

3M 08120

PPG 6500

Teroson 92

Terostat 9320 Semi-structural adhesive/anti-flutter material. Between

Unipart UBS605/6/7 bonded panels. Caulking gun.

Wurth 890100/1/2/3/4/5/6

Kent Industries 10075

3M 08401

3M 08694

PPG 6500 Seam sealer light. Between bonded panel edges.

Teroson 92 Hand applicator gun.

Teroson Light

Teroson 9320

Terostat 1K PU

Unipart UBS605/6/7

Wurth 890100/1/2/3/4/5/6

Gurit-Essex 10211

Gurit-Essex 10215

Gurit-Essex 10220

3M 08531 Seam sealer. Clinch joints (type b). Caulking gun.

3M 08537

3M 08703

3M 08783

3M 08788

GENERAL SPECIFICATION DATA

SEALING AND CORROSION PROTECTION

Materials applications (continued)

MANUFACTURER MATERIAL/JOINT TYPE

Kent Industries 10075

3M 08401 Seam sealer light. Clinch joints (type c). Caulking gun,

3M 08531 hand applicator gun.

Teroson Terolan Light

Kent Industries 10075

3M 08401

3M 08684

3M 08689

3M 08694 Seam sealer light. Gaps between panels (type a).

PPG 6500 Hand applicator gun.

Teroson 92

Terolan Light

Terostat 1K PU

Unipart UBS605/6/7

Wurth 890100/1/2/3/4/5/6

Kent Industries 10075

Kent Industries Putty

3M 08401

3M 08531

3M 08568

3M 08684

3M 08689 Seam sealer heavy. Gaps between panels (type b). Hand

3M 08694 applicator gun, applicator tube or caulking gun.

PPG 6500

Teroson 92

Terolan Light

Terostat 9320

Terostat 1K PU

Unipart UBS605/6/7

Wurth 890100/1/2/3/4/5/6

Gurit-Essex 10101

Gurit-Essex 10707

3M 08537

Gurit-Essex 10211

Gurit-Essex 10215 Brushable sealer. Overlap joints (e.g. floor pans).

Gurit-Essex 10220 Brush.

Teroson Brushable Sealer

Croda PW57

3M Cavity Waxes Cavity wax. Box members, sills. Injection equipment.

Unipart UBS508

GENERAL SPECIFICATION DATA NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

Materials applications (continued)

MANUFACTURER MATERIAL/JOINT TYPE

Croda PV75

3M 08861

3M 08877 Underbody sealing coat. Underbody. Schutz gun, aerosol.

Teroson Terotex Underseal

Unipart UBS410

Croda PW61

Dinol 205 Underbody wax coat. Underbody. Spray gun or brush.

Unipart PW61

Astors 3241/3

Croda PW197 Engine bay cosmetic wax/lacquer. Spray gun or brush.

Dinol 4010

3M Stone Chip Anti-chip coating. Sill panels. Schutz gun.

Coatings

3M 05900 Plastic Two-pack material. Repair of plastic parts.

Parts Repair Material Spreader or palette knife.

3M 08509 Dry glazed windscreen sealer. Applicator gun.

Unipart BHM605 Urethane butyl sealer for direct glazing. Caulking gun.

3M YS3998

3M Y387 Waterproof tape for sealing apertures. Hand application.

Unipart GS121

Evode Evo-Stik

3M 08030

3M 08034 Trim fixing adhesive. Brush or aerosol.

3M 08080

3M 08090

3M 08984 Adhesive cleaner/wax remover. Hand application with cloth.

GENERAL SPECIFICATION DATA

SEALING AND CORROSION PROTECTION

APPLICATION EQUIPMENT

SATA Schutz Gun Model UBE

Specifications:

Air consumption 200 litres/min. (7cu/ft. min.) @ 45PSI...............................................................

Weight 660grams (23.3oz)..............................................................................

Manufactured and supplied by:

Sata Gmbh

Minden Industrial Ltd.

16 Greyfriars Road

Moreton Hall

Bury St. Edmunds

Suffolk IP32 7DX

Tel. (01284) 760791

The Sata Schutz Gun is approved for the re-treatment

of vehicle underbody areas with protective coatings as

supplied in 1-litre (1.76pt.), purpose-designed,

’one-way’ containers. The screw thread fitting (female

on the gun) will fit most Schutz-type packs.

Full operating details are supplied with the equipment.

NOTE: Always clean gun after use with the

appropriate solvent.

Sata HKD1 Wax Injection Equipment

The Sata HKD1 is approved by Rover for use in all

cavity wax re-treatment operations. The equipment

comprises a high quality forged gun with 1-litre

capacity pressure feed container, a flexible nylon

lance, 1100mm (43.3in.) straight steel lance and

hooked wand lance. A quick-change coupling is a

standard fitting to enable lances to be easily

interchanged. The lances each have their own spray

pattern characteristics to suit the type of box section

to be treated.

The Sata HKD1 is covered by a 12 month warranty.

All replacement parts and service are obtainable from

the suppliers.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

Cooper Pegler Falcon Junior Pneumatic (Airless)

Manufacturer and supplier:

Cooper Pegler & Co. Ltd.

Burgess Hill

Sussex RH15 9LA

Tel. 04 446 42526

Intended primarily for applying transit wax, the Falcon

Junior pneumatic sprayer has a 5-litre (1 gal.)

container with integral hand pump. This high quality

unit provides a simple and effective means of wax

spraying without the need for compressed air or

additional services.

A selection of nozzles, lances and hoses together with

a trigger valve assembly incorporating a filter enable

the sprayer to be used in a variety of applications.

These include general maintenance, wax injection and

paint application. All parts are fully replaceable and

include a wide range of nozzle configurations.

The Falcon Junior is fitted with Viton seals and is

guaranteed for 12 months.

3M Application Equipment

Manufacturer:

3M UK PLC

Automotive Trades Group

3M House

PO Box 1

Market Place

Bracknell

Berks. RG12 1JU

Tel. (01344) 858611

All 3M equipment is available from local trade factors

or 3M refinishing factors.

3M Caulking Gun 08002

A lightweight, robust metal skeleton gun designed to

accommodate 325mm (12.8in.) cartridge for

dispensing sealants etc. This gun facilitates rapid

cartridge loading and features a quick-release lever

for accurate material ejection and cut-off control.

3M Pneumatic Cartridge Gun 08012

An air line fed gun for application of 3M cartridge

products. Excellent ease of application for a smooth

sealant bead, and incorporates a regulator valve for

additional control.

Other 3m applicator equipment available:

3M Pneumatic Applicator Guns

Air line fed gun for application of 3M sachet sealers

(Part No. 08006 for 200ml [6fl/oz.] and 310ml [9fl/oz.]

sachets, and Part No. 08007 for all size sachets

including 600ml [18fl/oz.]).

3M Applicator Gun 08190

For application of 3M Structural Adhesive 08120.

3M Inner Cavity Wax Applicator Gun

Features 750mm (29.6in.) flexible tube and using

1-litre (1.76pt.) canisters, this approved equipment is

available from all 3M refinishing factors.

Other 3m applicator equipment available:

Heavy Duty Manual Gun.

GENERAL SPECIFICATION DATA

SEALING AND CORROSION PROTECTION

MATERIALS GUIDE

3M Automotive Structural Adhesive 08120

a two-part epoxy structural adhesive, with ’automix’

twin-cartridge dispenser. For doorskin and for bonding

panel stiffeners. Supplied as twin pack for use in small

trigger gun (No. 08190).

3M Bolted Panel Sealer 08572

Preformed strip 20mm (0.8in.) wide x 2mm (0.08in.)

thick supplied in 4.6 metre (81.2in.) reels.

Permanently flexible with good adhesion, for sealing

wing to body joints and other bolted or riveted panels.

3M Body Caulking 08568

Thumb-applied sealing compound supplied in

60-packs of preformed strips 300mm (11.8in.) long x

6mm (0.24in.) wide. For sealing large openings and

fissures. Non-hardening, does not dry out or crack,

can be overpainted immediately.

3M Drip-Chek Sealer Heavy 08531

For use on vertical fissures and seams up to 3mm

(0.12in.) wide for a firm but flexible seal which will not

harden or shrink. Self-levelling, will not sag on vertical

surfaces. May be worked with a tool or smoothed with

a wet finger.

Supplied in 150ml (4.5fl/oz.) tubes.

3M Drip-Chek Sealer Clear 08401

An easily flowing sealer similar to Drip-Chek Heavy

but of clear consistency. Ideal for an almost invisible

spot weal over finished paintwork. Can be overpainted

or even mixed with paint colour to form a self-coloured

sealant.

Supplied in 150ml (4.5fl/oz.) tubes.

3M Super Seam Sealer 08537

A brushable sealer designed to simulate original

factory-applied sealer on all overlap joints such as

floor pans, wheel arches, boot and load space seams

and fuel filler cap surrounds. Resistant to oil, petrol

and water. Should be brushed on in ONE direction

only for best results.

WARNING: Must be stored under

conditions applicable to highly flammable

materials.

3M Flexseal 08684, 08689 AND 08694

A high solid, non-shrinking, polyurethane body sealer

for use in either a hand gun or pneumatic applicator

gun. Excellent adhesion and sealing properties.

Resistant to oil, petrol and water. Supplied in 310ml

(9fl/oz.) cartridges and in a choice of black, white or

grey.

3M Polyurethane Sachet Sealer 08703, 08783,

08788

Similar to Flexseal polyurethane but available in

collapsible foil sachets in 310ml (9fl/oz.) and 600ml

(18fl/oz.) sizes with a choice of three colours: black,

grey or white.

3M Windscreen Sealer 08509

Non-hardening sealant for dry-glazed,

weatherstrip-type windscreens. Applied with applicator

gun.

Supplied in 310ml (9fl/oz.) cartridges.

3M Spray Schutz 08877, Body Schutz 08861

Flexible, rubberised, fast-drying coating which dries to

a black textured finish.

Spray Schutz supplied in 600ml (18fl/oz.) aerosols.

Spray Schutz and Body Schutz also supplied in 1-litre

(1.76pt.) cartridges to fit Schutz Gun.

GENERAL SPECIFICATION DATA NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

3M Flexible Parts Repair Material 05900

A fast-curing, two-part system for repairing minor

damage to plastic bumpers, spoilers, valances etc.

Dries in 30 mins.

Supplied as two-pack 320ml (10fl/oz.) kit.

3M Weld Thru’ SEALER 08625

For anti-corrosion protection between spot welded

panels. Brush application.

Supplied in 1-litre (1.76pt.) canisters.

3M Bodygard

Rubber-based, stone chip protective coating for

panels. Fast drying, low bake compatible and may be

overpainted. Varying textures obtainable depending

on type of finish required. Available in black (1-litre

[1.76pt.] pack 08858, aerosol 08158) or grey (1-litre

[1.76pt.] pack 08859, aerosol 08159).

3M Inner Cavity Wax

For protective coating on inner panels. Excellent

anti-corrosion properties. Available in transparent or

amber consistencies, and 1-litre (1.76pt.) canister or

500ml (0.88pt.) aerosol packs.

3M Zinc Spray 09113

Anti-corrosive coating for spot welding applications on

joints and seams. Supplied in 500ml (0.88pt.) aerosol

packs.

3M Waterproof Cloth Tape YS3998

Black waterproof tape for sealing door apertures and

body box section access holes. Long-lasting,

moisture-resistant adhesive will withstand immersion

in water.

Supplied in 50-metre (164.2ft.) rolls in a variety of

widths.

3M Adhesive Cleaner and Wax Remover 08984

For surface preparation before application of most

types of adhesive, coating and sealant, also for

removal of tar, silicone polish, wax, grease and oil.

Non-staining. May also be used for cleaning adhesive

remnants from sander disc backing pads.

Supplied in 1-litre (1.76pt.) canisters.

ELECTRONIC AIR SUSPENSION

DESCRIPTION AND OPERATION

ELECTRONIC AIR SUSPENSION - EAS

Description

The Range Rover concept of air supension is already

well established, the system fitted to the New Range

Rover is broadly similar. Progressive development

has resulted in added features to improve the control

and operation of the system.

Air springs provide a soft and comfortable feel to the

ride of the vehicle. The use of a microprocessor to

control the system exploits the advantages of air

suspension.

The system provides a near constant ride frequency

under all load conditions resulting in:

• Improved ride quality

• Consistency of ride quality

• Constant ride height

• Improved headlamp levelling

The system provides five ride height settings plus self

levelling. Each setting is automatically maintained at

the correct height by the system logic with the

minimum of driver involvement. Vehicle height is

sensed by four rotary potentiometer type height

sensors. Height information from each sensor signals

the electronic control unit (ECU) to adjust each air

spring by switching the solenoid valves to hold, add or

release air.

The five height settings are as follows:

Standard: Profile

Low profile: 25 mm (1 in.) below standard.

Access: 65 mm (2.6 in.) below standard. Crawl: It is

possible to drive at the access ride height at speeds

less than 32 km/h (20 mph), where headroom is

restricted.

High profile: 40 mm (1.6 in.) above standard.

Extended profile: 70 mm (2.75 in.) above standard.

This setting is not manually selectable.

Self levelling

On a coil sprung vehicle the effect of adding weight is

for the vehicle to lean either from front to back or side

to side unless the increased weight is evenly spread.

With air suspension, the system detects this body lean

and automatically compensates for it. The vehicle will

self level to the lowest corner height for 20 seconds

each time the driver exits vehicle and closes the

doors.

The system will check vehicle height every 6 hours

and make minor corrections, not exceeding 8 mm,

(0.31 in) as necessary.

When unloading through the tailgate the system will

self level to compensate for the decreased load after

door closure.

NOTE: If the vehicle is parked on uneven

ground or with a wheel or wheels on the

kerb, self levelling will lower the vehicle to

the lowest spring height.

CAUTION: The underside of the vehicle

must be kept clear of any obstacles while

the vehicle is parked, as self levelling may

result in a reduced trim height.

WARNING: Before commencing work

which requires access to the underside or

wheel arches of the vehicle, the

suspension must be allowed to relevel.

Relevelling is achieved by opening and closing of

any of the side doors, while all other doors and

tail gate remain closed, and the ignition off.

EAS must be set in ’high-lock’ using TestBook,

during any work which does not require chassis

to axle displacement. This will hold the

suspension in extended profile position, until

reset by TestBook.

FRONT SUSPENSION NEW RANGE ROVER

DESCRIPTION AND OPERATION

LOCATION OF COMPONENTS

Key to location of components

1. Electrical control unit

2. Compressor

3. Air dryer

4. Valve block

5. Reservoir

6. Height sensors front

7. Height sensors rear

8. Front air spring

9. Rear air spring

10. Relays, fuses

11. Driver controls

ELECTRONIC AIR SUSPENSION

DESCRIPTION AND OPERATION

DESCRIPTION OF COMPONENTS

Electrical control unit - ECU

The ECU is located underneath the front left hand

seat. The ECU maintains the requested vehicle ride

height by adjusting the volume in each air spring. It is

connected to the cable assembly by a 35 way

connector. To ensure safe operation the ECU has

extensive on board diagnostic and safety features.

The ECU must be replaced in case of failure.

Air compressor

NOTE: The air compressor and valve block

are contained in the under bonnet unit

mounted on the left hand inner wing.

The air compressor provides system pressure. A

thermal switch is incorporated which cuts out

compressor operation at 120˚ C. An air filter is fitted to

the compressor head. The filter is renewed every

40,000 kms. (24,000 miles).

Air dryer

The air dryer is connected into the air line between the

compressor and reservoir. It is mounted on the engine

air cleaner box. The dryer removes moisture from

pressurised air entering the system. All air exhausted

from the system passes through the dryer in the

opposite direction. The air dryer is regenerative in that

exhaust air absorbs moisture in the dryer and expels it

to atmosphere.

The air dryer is non-servicable, designed to last the

life of the vehicle. However, if any water is found in

the system, the air dryer must be replaced.

CAUTION: If the air dryer is removed from

the vehicle the ports must be plugged to

prevent moisture ingress.

Valve block

The valve block controls the direction of air flow. Air

flow to and from the air springs is controlled by seven

solenoid operated valves, one for each spring plus an

inlet, exhaust and outlet. In response to signals from

the ECU, the valves allow high pressure air to flow in

or out of the air springs according to the need to

increase or decrease pressure. A diaphragm valve

operated by the solenoid outlet valve ensures that all

exhausted air passes through the air dryer.

Mounted on the valve block is a pressure switch which

senses air pressure and signals the ECU to operate

the compressor when required.The compressor will

operate when the pressure falls between 7.2 and 8.0

bar. It will cut out at a rising pressure of between 9.5

and 10.5 bar.

The valve block contains the following serviceable

components: solenoid coils 1 to 6, drive pack and

pressure switch.

The valve block must only be dismantled after the

correct diagnosis procedure.

Reservoir

The 10 litre reservoir is mounted on the right hand

side of the chassis. One connection acts as air inlet

and outlet for the rest of the system. The reservoir

stores compressed air between set pressure levels.

The reservoir drain plug requires removing to check

for moisture in the system every 40,000 kms. (24,000

miles).

Height sensors

Four potentiometer type height sensors signal vehicle

height information to the ECU. The potentiometers are

mounted on the chassis and activated by links to the

front radius arms and rear trailing links. A height

sensor must be replaced in case of failure, and the

vehicle recalibrated using TestBook.

FRONT SUSPENSION NEW RANGE ROVER

DESCRIPTION AND OPERATION

Air springs - front and rear

The air springs consist of the following components:

1. Top plate

2. Rolling rubber diaphragm

3. Piston

Front and rear air springs are of similar constuction

but are NOT interchangeable. The diaphragm is not

repairable, if failure occurs the complete air spring

must be replaced

Driver controls

Mounted in the centre of the dashboard, the driver

controls consist of an UP/DOWN switch, an INHIBIT

switch and a height setting indicator. For full

description.

See this section.

Relays, fuses

Located in the under bonnet fuse/relay box are 2

relays, plus 10, 20 and 30 amp fuses.

DRIVER CONTROLS

The driver controls are located in the centre of the

fascia. The controls consist of:

1. The HEIGHT CONTROL is a press and release

type rocker switch which is used to select the

required ride height. The vehicle will not respond

until switch is released. All movements selected

by operation of this switch are indicated by the

ride height indicator lights located next to the

switch.

2. The INHIBIT switch is a mechanically latching

switch. When selected it modifies the automatic

height changes of the system, for further details.

See Electrical Trouble Shooting Manual.

Selection of ’inhibit’ is indicated by illumination of

the switch tell-tale lamp, which is also bulb

tested with the ride height indicator.

3. High indicator light.

4. Standard indicator light.

5. Low indicator light.

6. Access indicator light.

7. Instrument pack warning light.

Indicator lights

When the ignition key is turned to position 2 all four

indicator lights, the air suspension warning light and

the inhibit switch will be illuminated continuously.

When the engine is started, the lights will remain

illuminated for 2 seconds, after which the current ride

height will be indicated. Two indicators will be

illuminated if the vehicle is between ride heights, with

the selected height flashing. When the new height is

achieved the indicator will be illuminated constantly

and the previous height indicator extinguished. The

inhibit switch indicator is illuminated while it is

activated. Both switches are illuminated with sidelights

switched on. Additional driver information is given by

the message centre in the instrument pack. For details

of the messages.

See this section.

Air suspension warning lamp

This amber lamp is located in the instrument pack.

The lamp will be constantly illuminated when driving at

high ride height and will flash when vehicle is at

extended height. The lamp will also illumunate if a

fault within the system is detected. A bulb check is

provided when the ignition switch is turned to position

2 and for 2 seconds after vehicle start.

ELECTRONIC AIR SUSPENSION

DESCRIPTION AND OPERATION

HEIGHT SETTINGS

Standard ride height

With the Inhibit switch off (unlatched), at speeds

below 80 km/h (50 mph) the standard ride height

indicator will be illuminated.

Standard vehicle ride height is maintained under all

load conditions. This also maintains headlamp

levelling.

Low ride height

Low ride height is automatically selected when the

vehicle speed exceeds 80 km/h (50 mph) for at least

30 seconds with the inhibit switch off. Low ride height

indicator lamp will flash during height change and

standard ride height indicator will extinguish when low

ride height is attained.

Standard ride height is automatically selected when

the vehicle speed drops below 56 km/h (35 mph) for

at least 30 seconds with the inhibit switch off.

The driver can select low ride height at any speed.

With the vehicle at low ride height, depressing the

inhibit switch (latched) will result in the vehicle

maintaining low ride height regardless of speed.

The height control switch can be used to change

between low and standard ride heights regardless of

speed.

Access mode

This position eases access to and from the vehicle.

With the vehicle stationary, doors and tailgate closed,

park brake applied, foot brake released and gearshift

in ’Park’ on automatic vehicles, press and release the

down switch. The vehicle will descend to access

mode. While the vehicle is descending, the access

indicator will flash. When access mode is attained, the

indicator will remain constantly illuminated, and

standard ride height lamp will be extinguished.

Access mode can be selected up to 40 seconds

before stopping vehicle. On stopping, applying the

handbrake, releasing the foot brake and selecting

’Park’ on automatic vehicles, the vehicle will lower to

access mode.

It is possible to select access up to 40 seconds after

switching engine off.

NOTE: Opening a door or tailgate will

immediately stop vehicle height change.

When the door is closed, the height

change will be completed. If the door is open for

more than thirty seconds, the system will need

’reminding’ of the new height when the door is

closed.

Driving the vehicle will result in vehicle rising

automatically to standard ride height. Alternatively

standard ride height can be achieved by closing all

doors, starting engine and pressing the up switch. The

standard indicator will flash during the change. When

standard ride height is attained the indicator will

remain constantly illuminated and access indicator will

be extinguished.

Crawl mode

In areas where height is restricted, the vehicle may be

driven in access mode. To achieve this, ensure the

inhibit switch is unlatched and select access mode.

When access height is achieved, press the inhibit

switch, the lamp will be illumunated. The message

centre in the instrument binnacle will beep three times

and display AIRSUS ISOLATED. The vehicle may

now be driven at speeds up to 32 km/h (20 mph).

If the vehicle is accelerated to 16 km/h (10 mph) the

message centre will beep three times and display

SLOW 20 MPH (32 KM/H) MAX.

If speed exceeds 40 km/h (25 mph) the vehicle will

rise to low profile, with low warning flashing. On

slowing to 32 km/h (20 mph) the vehicle will lower to

access mode with access warning illuminated.

When speed falls below 8 km/h (5 mph) the message

centre will beep three times and display AIRSUS

ISOLATED.

To cancel crawl mode, release the inhibit switch or

depress the up switch.

FRONT SUSPENSION NEW RANGE ROVER

DESCRIPTION AND OPERATION

High ride height

This position is used to improve approach and

departure angles and when wading. When at standard

ride height, pressing the up switch will select high ride

height provided the road speed is below 56 km/h (35

mph). The high ride height indicator will flash during

the height change. When the change is complete the

indicator will remain constantly illuminated, and

standard ride height indicator will be extinguished.

The indicator in the instrument pack will also be

illuminated. If speed exceeds 56 km/h (35 mph), the

vehicle will return to standard profile.

Extended ride height

This position is achieved if chassis is grounded

leaving wheel or wheels unsupported. Initial ECU

reaction is to lower (deflate) affected springs. After a

timed period the ECU detects no height change, it

therefore reinflates springs to extended profile in an

attempt to regain traction. The position will be held for

10 minutes, after which time the vehicle will

automatically return to standard ride height.

Pressing the down switch will lower vehicle 20 mm to

high profile.

If vehicle speed exceeds 56 km/h (35 mph) the

vehicle will immediately lower to standard ride height.

This speed could be achieved, for example, by

wheelspin.

VEHICLE TRANSPORTATION

New vehicles are transported from the factory with the

EAS system electronically ’frozen’ in access mode.

When road speed exceeds 40 km/h (25 mph), the

vehicle will rise to low ride height. It will return to

access mode if speed falls below 38.4 km/h (24 mph).

This condition is cancelled at pre-delivery inspection,

by entering the appropriate command via TestBook.

Vehicle transportation/recovery

CAUTION: When an air suspension vehicle

is secured to a transporter using the

chassis lashing eyes, there is a possibility

due to air leakage, self levelling or operation of

ride height controls that the tension of the

securing straps will be lost. To prevent this the

ride height should be set to access mode before

securing to transporter.

If the engine cannot be run and the vehicle is not in

access mode, the vehicle can be transported, but it

must be secured to the transporter by the roadwheels,

not the chassis.

ELECTRICAL TROUBLESHOOTING

For electrical details of the air suspension circuit.

See

Electrical Trouble Shooting Manual.

ELECTRONIC AIR SUSPENSION

DESCRIPTION AND OPERATION

SYSTEM OPERATION

Numbers refer to pneumatic circuit diagram

Air is drawn through the inlet filter (1) to the

compressor (2), where it is compressed to 10 æ 0,5

bar.

Compressed air passes to the air dryer (3) where

moisture is removed as it flows through the dryer

dessicant. The dessicant in the lower portion of the

dryer becomes wet.

Dried air passes through a non-return valve NRV1 to

the reservoir (4).

The 3 non-return valves (6) ensure correct air flow.

They also prevent loss of spring pressure if total loss

of reservoir pressure occurs.

The pressure switch (5) maintains system pressure

between set limits by switching on and off the

compressor via an ECU controlled relay.

For air to be admitted to an air spring (10), the inlet

valve (7) must be energised together with the relevant

air spring solenoid valve (9).

For air to be exhausted from an air spring, the exhaust

valve (8) must be energised together with the relevant

air spring solenoid valve.

The solenoid diaphragm valve (12) ensures that all air

exhausted to atmosphere passses through the dryer.

Exhausted air passes vertically downwards through

the dryer. This action purges moisture from the

dessicant and regenerates the air dryer.

Air is finally exhausted through the system air

operated diaphragm valve (13) and to atmosphere

through a silencer (14) mounted below the valve

block.

FRONT SUSPENSION NEW RANGE ROVER

DESCRIPTION AND OPERATION

FRONT SUSPENSION

Description

The front suspension design on the New Range Rover

allows maximum wheel travel and axle articulation,

providing good ground clearance without loss of

traction or directional stability.

Near constant ride frequency under all load conditions

is achieved by utilizing advancements in suspension

geometry complemented to control and operation of

the air suspension system.

See this section.

Front axle suspension

1. Radius arms

2. Panhard rod

3. Shock absorbers

4. Bump stops

5. Anti-roll bar

6. Air springs

7. Front axle

ELECTRONIC AIR SUSPENSION

DESCRIPTION AND OPERATION

Long front radius arms (1) are fitted to the front axle

(7) and provide maximum axle articulation which is

vital for off road performance. The radius arm,

comprising a forged steel link with twin front

mountings using ferrule rubber bushes, is secured to

fabricated mounting brackets welded to the front axle.

Flexible rubber bushes are used on a stem end joint

to secure the rear of the radius arm to a mounting on

the chassis cross member as shown in 60M7040. The

vehicle height sensors are also linked to the front

radius arms; for full details of the height settings.

See

this section.

A panhard rod (2), which ensures that the axle

remains centrally located, is fitted transversely and

also uses ferrule rubber bush mountings at both axle

and chassis locations. An anti-roll bar (5) is fitted to

the front axle to control body roll and directional

stability. Two rubber bearing bushes, with retaining

straps, secure the anti-roll bar to the front axle, while

ball jointed links, suspended from the chassis, support

the rear of the anti-roll bar.

Conventional telescopic shock absorbers (3), used to

control body movement, are secured to fabricated

towers which are welded to the chassis. The upper

fixing uses a single retaining bolt passing through a

flexible rubber bush. The lower fixing of the shock

absorber comprises of a stem type mounting with two

flexible rubber bushes and support washers secured

to an axle mounting by a single retaining nut. Cellular

foam bump stops (4) are fitted under the chassis

adjacent to the air springs (6) and prevent possible

damage that could occur should there be excessive

axle to chassis movement. Should there be a loss of

air pressure in the air springs the vehicle can still be

driven safely at a speed not exeeding 35 mph (56kph)

with the bump stops resting on the axle, although this

will result in a hard ride. The loss of air pressure

should be investigated as soon as possible. The bump

stops are ’progressive’ and will reform from a

compressed state when the load is released.

SUPPLEMENTARY RESTRAINT SYSTEM

DESCRIPTION AND OPERATION

SYSTEM COMPONENTS - DISTRIBUTED SRS

SYSTEM

1. Airbag crash sensors

2. SRS warning light (airbag)

3. Rotary coupler

4. Driver’s airbag module

5. Passenger’s airbag module

6. Airbag diagnostic socket

7. Airbag diagnostic control unit

8. Airbag harness

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

DESCRIPTION AND OPERATION

OPERATION

The airbag supplementary restraint system (SRS) is a

safety device which, when used in conjunction with

the seat belt, is designed to protect the driver and

front passenger by operating when the vehicle

receives a frontal impact (in the area shown)

exceeding a certain set speed.

In the event of a frontal impact, when the airbag

diagnostic control unit and one of the airbag crash

sensors senses the impact, the diagnostic control unit

triggers the airbag modules which fires an igniter. This

in turn ignites tablets of sodium azide which generate

a large amount of Nitrogen gas leading to airbag

inflation in approximately 30 milli-seconds.

When fully deployed the airbag offers additional

protection to the front seat occupant. As an occupant

moves into the airbag it immediately discharges the

gas from vent holes to provide progressive

deceleration and reduce risk of injuries. The whole

process is completed in approximately 0.3 seconds.

WARNING: All the airbag system

components, including the wiring harness,

MUST be renewed after the airbags have

deployed.

SRS warning light (airbag)

The warning light in the instrument pack illuminates

after the electrical circuits are switched on whilst a

system check is carried out. After about 7 seconds the

warning light will go out. The system checks the

airbag diagnostic control unit, airbag crash sensors

and the airbag harness.

In the event of a fault in the system the warning light

will lluminate and begin modulating. The airbag

diagnostic control unit logs the fault which can only be

accessed using TestBook .

SUPPLEMENTARY RESTRAINT SYSTEM

DESCRIPTION AND OPERATION

SYSTEM COMPONENTS - SINGLE POINT SENSED

SRS SYSTEM

1. SRS warning light (airbag)

2. Rotary coupler

3. Driver’s airbag module

4. Passenger’s airbag module

5. Airbag diagnostic socket

6. Airbag diagnostic control unit (DCU)

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

DESCRIPTION AND OPERATION

OPERATION

The airbag supplementary restraint system (SRS) is a

safety device which, when used in conjunction with

the seat belt, is designed to protect the driver and

front passenger in the event of a frontal collision.

The diagnostic control unit (DCU) is able to distinguish

between rough road conditions and a frontal collision.

If the DCU detects a frontal collision of sufficient

severity, it sends a fire signal to the airbag module

initiators. The initiators ignite tablets of sodium azide

which generate a large amount of Nitrogen gas

leading to airbag inflation in approximately 30

milli-seconds.

As the occupant moves into the fully inflated airbag,

the nitrogen gas discharges from vent holes in the

rear of the airbag. As the airbag deflates, it provide

progressive deceleration for the occupant and

reduces the risk of injuries. The process from airbag

initiation to deflation is completed in approximately 0.3

seconds.

WARNING: All the airbag system

components, including the wiring harness,

MUST be renewed after airbag

deployment.

SRS warning light

The airbag system carries out a system check every

time the ignition is switched to position 2. During the

system check, the instrument pack warning light is

illuminated to provide a bulb check. The warning lamp

is extinguished when the system check is complete,

after about 5 seconds.

If a system fault is found during the initial system

check or subsequently during driving, the warning light

will illuminate, indicating to the driver that there is a

fault with the airbag system. With the warning light on,

the airbag system will not operate in the event of a

frontal collision. The DCU records system faults in an

internal memory. The memory can be interrogated

using TestBook via the diagnostic socket located on

the passenger side fascia closing panel.

SUPPLEMENTARY RESTRAINT SYSTEM

PRECAUTIONS

GENERAL PRECAUTIONS

Making the system safe

Before commencing repair work on any airbag

components:

• Remove the key from the starter switch.

• Disconnect both battery leads, earth lead

first.

• Wait 10 minutes for DCU back-up power

circuit to discharge.

Care Points

WARNING: The airbag module contains

Sodium Azide which is poisonous and

extremely flammable. Contact with water,

acid or heavy metals may produce harmful or

explosive compounds. Do not dismantle,

incinerate or bring into contact with electricity.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

PRECAUTIONS

NEVER

• Drop any airbag system component.

NOTE: The airbag DCU is a shock

sensitive device and must be handled with

extreme care.

• Wrap arms around an airbag module.

• Attach anything to the airbag cover.

• Attempt to repair any component.

• Apply electrical power to a component

unless instructed to do so by an approved

test procedure.

• Transport airbag modules in the passenger

compartment of a car. Use the luggage

compartment.

• Install any airbag component that shows

signs of being dropped or improperly

handled, such as dents, cracks or

deformation.

• Install used airbag components from

another vehicle. When repairing an airbag

system, use only genuine new parts.

ALWAYS

• Carefully inspect any airbag component

before installation.

• Check airbag harness is correctly routed.

• Check airbag connectors are fully mated

and latched after completion of work.

Airbag handling and storage

• Do not try to dismantle the airbag module.

It has NO serviceable parts. Once an

airbag has been deployed, it cannot be

repaired or reused.

• Be careful that the airbag module receives

no strong shocks, it could deploy.

• Special bolts are necessary for installing

the airbag module. Do not use other bolts.

For temporary storage of the airbag module during

service, observe the following precautions.

• Always keep components dry.

• Always carry the airbag module with the

pad surface face up.

• Store the removed airbag module with the

pad surface face up.

• Do not allow anything to rest on the airbag

module.

• Place the airbag module in the designated

storage area.

SUPPLEMENTARY RESTRAINT SYSTEM

PRECAUTIONS

• If no designated storage area is available,

then the luggage compartment of the

vehicle should be used. Always lock the

luggage compartment when an airbag

module is stored in it and inform the

workshop supervisor.

WARNING: If the airbag module is

improperly stored face down, accidental

deployment could propel the unit with

enough force to cause serious injury.

• Store the removed airbag assembly on a

secure flat surface away from any electrical

equipment or high heat source (exceeding

85˚ C/185˚ F) and free of any oil, grease,

detergent of water.

CAUTION: Improper handling of storage

can internally damage the airbag module,

making it inoperative. If you suspect the

airbag module has been damaged, install a new

unit and refer to the Deployment/Disposal

Procedures for disposal of the damaged airbag.

Overnight storage

Airbag modules are classed as explosive devices and

as such must be stored in an approved secure steel

cabinet which has been registered by the local

authority.

CRASH SENSOR INSPECTION - DISTRIBUTED

SRS SYSTEM ONLY

1. After any degree of front body damage, inspect

both front crash sensors. Replace a sensor if

there are any signs of dents, cracks or

deformation.

2. Ensure the sensors are installed correctly. There

must be no gap between the sensor and body of

the vehicle. Use the fixing screws supplied with

the sensor and tighten to the correct torque.

Tighten front sensor fixing before rear sensor

fixing.

CAUTION: Take extra care when painting

or doing body work in the vicinity of the

sensors. Avoid direct exposure of the

sensors or harness to heat guns, welding or

spraying equipment.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

PRECAUTIONS

WIRING AND CONNECTORS

• Never attempt to modify, splice or repair

the airbag wiring. Never install electronic

equipment such as; a mobile telephone,

two-way radio or in-car entertainment

system in such a way that it interferes

electrically with the airbag wiring.

• Always ensure airbag wiring is routed

correctly. Be careful to avoid trapping or

pinching the airbag wiring. Look for

possible points of chaffing.

• Always use specified earth fixings

tightened to the correct torque. Poor

earthing can cause intermittent problems

that are difficult to diagnose.

• Ensure all airbag harness connectors are

mated correctly and securely fastened. Do

not leave the connectors hanging loose.

SUPPLEMENTARY RESTRAINT SYSTEM

PRECAUTIONS

WARNING LABELS

A combination of symbols/icons are displayed (either

in a suitable, prominent position or attached to the

component itself) to indicate:

• The need for caution when working in close

proximity to SRS components.

• The publication where suitable reference

and advice can be found (usually Repair

Manual or Owner’s Handbook).

NOTE: It is imperative that before any work

is undertaken on the SRS system that the

appropriate publication is read and

understood.

The following list indicates current locations for

warning lables. Exact positions may vary dependent

on legislation and market trends.

1. Bonnet locking platform. Refer to Owner’s

Handbook for information on the SRS system.

2. Driver’s and passenger’s sun visor. Refer to

Owner’s Handbook for information on the SRS

system.

3. End of fascia, passenger’s side (not all markets).

Do not use rear facing child seat in passenger

seat of vehicles fitted with passenger airbag.

4. Rotary coupler. Ensure wheels are positioned in

straight ahead position before removal and

refitting. Do not rotate mechanism. Refer to the

Repair Manual for information on the airbag

system.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

PRECAUTIONS

5. Airbag modules

A- Land Rover bar code. The code number(s) must be

recorded if the airbag module is to be replaced.

B- Warning, the use of gas generators is permitted

only for occupant restraint systems in vehicles fitted

with airbags. Not repairable. Handling is permitted

only by authorized personnel. Do not use any live

electrical test equipment. Do not open, remove or

install in another vehicle. Risk of malfunction and

personal injury. Upon deployment, an airbag unit

which is not properly mounted may become a

dangerous projectile. Refer to Repair Manual for

further instructions.

C- Danger Poison. Keep out of reach of children.

Contains sodium azide and sodium nitrate. Contents

are poisonous and extremely flammable. Contact with

acid or heavy metals may produce toxic gases.

VEHICLE RECOVERY

Towing - airbag not deployed

Normal towing procedures are unlikely to cause an

airbag to deploy. However, as a precaution, switch the

ignition off and then disconnect both battery leads.

Disconnect the negative lead first.

Towing - airbag deployed

Once the driver’s airbag has been deployed the

vehicle must have a front suspended tow. However,

as a precaution, switch the ignition off and then

disconnect both battery leads. Disconnect the

negative ’-’ lead first.

SUPPLEMENTARY RESTRAINT SYSTEM

PRECAUTIONS

AIRBAG MANUAL DEPLOYMENT

If a vehicle is to be scrapped and contains an

undeployed airbag module, the module must be

manually deployed. This operation should only be

carried out using the following recommended manual

deployment procedure.

Before deployment is started, the deployment tool self

test should be carried out.

Deployment tool SMD 4082/1 self test procedure

1. Insert blue and yellow connectors of tool lead

into corresponding sockets on face of tool.

2. Connect crocodile clips of second tool lead to

battery, red to positive and black to negative.

3. Red "READY" light should illuminate.

4. Press and hold both operating buttons.

5. Green "DEFECTIVE" light should illuminate.

6. Release both operating buttons.

7. Red "READY" light should illuminate.

8. Disconnect tool from battery.

9. Disconnect blue and yellow connectors from tool

face sockets.

10. Self test now complete.

Deployment with module fitted to vehicle

These guidelines are written to aid authorised

personnel to carry out the safe disposal of the airbag

module when fitted to the vehicle.

WARNING: Only use the Land Rover

approved deployment equipment. Deploy

airbag modules in a well ventilated,

designated area. Ensure airbag module is not

damaged or ruptured before deploying.

Driver’s airbag module

1. Carry out deployment tool self test.

2. Remove driver’s side fascia closing panel.

See

CHASSIS AND BODY, Repair.

3. Release airbag multiplug from fascia and

disconnect multiplug.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

PRECAUTIONS

WARNING: Ensure tool SMD 4082/1 is not

connected to battery.

4. Connect flylead SMD 4082/5 to airbag

connector.

5. Connect flylead SMD 4082/5 to tool SMD

4082/1.

WARNING: Ensure airbag module is

secure within steering wheel.

6. Connect tool SMD 4082/1 to battery.

WARNING: Ensure all personnel are

standing at least 15 metres away from

vehicle.

7. Press both operating buttons to deploy airbag

module.

8. DO NOT return to airbag module for 30 minutes.

9. Using gloves and face mask, remove airbag

module from steering wheel, place airbag

module in plastic bag and seal bag.

10. Transport deployed airbag module to designated

area for incineration.

NOTE: DO NOT transport airbag module in

the vehicle passenger compartment.

11. Scrap all remaining parts of airbag system. DO

NOT re-use or salvage any parts of the airbag

system, including steering wheel or steering

column.

SUPPLEMENTARY RESTRAINT SYSTEM

PRECAUTIONS

Passenger’s airbag module

1. Carry out deployment tool self test.

2. Remove glove box assembly.

See CHASSIS

AND BODY, Repair.

3. Release airbag connector from fascia and

disconnect multiplug.

WARNING: Ensure tool SMD 4982/1 is not

connected to battery.

4. Connect flylead SMD 4082/5 to harness

connector.

5. Connect flylead SMD 4082/5 to tool SMD

4082/1.

WARNING: Ensure airbag module is

secure within fascia.

6. Connect tool SMD 4082/1 to battery.

WARNING: Ensure all personnel are

standing at least 15 metres away from

vehicle.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

PRECAUTIONS

7. Press both operating buttons to deploy airbag

module.

8. DO NOT return to airbag module for 30 minutes.

9. Using gloves and face mask, remove airbag

module from fascia. Place airbag module in

plastic bag adn seal bag.

10. Transport deployed airbag module to designated

area for incineration.

NOTE: DO NOT transport airbag module in

the vehicle passenger compartment.

11. Scrap all remaining parts of airbag system. DO

NOT re-use or salvage any parts of the airbag

system.

Following the deployment of the airbags, the following

components must be replaced:

SRS wiring harness,

Airbag crash sensors (distributed system only),

Rotary coupler,

Driver’s airbag module,

Passenger’s airbag module,

Airbag diagnostic control unit,

Complete steering wheel assembly including

associated switches.

PRECAUTIONS

Dimensions ’A’ AND ’B’ on steering column must be

within tolerance.

Dimension ’A’ 3.0 - 4.0 mm

Dimension ’B’ 91.5 - 92.8 mm

If dimension ’A’ is incorrect replace steering column.

If dimension ’B’ is incorrect replace steering column,

and pedal box.

SUPPLEMENTARY RESTRAINT SYSTEM

PRECAUTIONS

Deployment with module removed from vehicle

These guidelines are written to aid authorised

personnel to carry out the safe disposal of airbag

modules when removed from the vehicle.

WARNING: Only use Land Rover approved

deployment equipment. Deploy airbag

modules in a well ventilated, designated

area.

Driver’s airbag module

1. Carry out deployment tool self test.

2. Remove airbag module from steering wheel.

See Repair.

3. Position tool SMD 4082/2 in vice, ensuring that

vice jaws grip tool above bottom flange to

prevent possibility of tool being forced upwards

from vice. Tighten vice.

4. Secure airbag module to tool SMD 4082/2.

Ensure module is correctly secured using both

fixings.

5. Ensure airbag module mounting brackets are

secure.

WARNING: Ensure tool SMD 4082/1 is not

connected to battery.

6. Connect flylead SMD 4082/4 to airbag module.

7. Connect flylead SMD 4082/4 to tool SMD

4082/1.

WARNING: Do not lean over module whilst

connecting.

8. Connect tool SMD 4082/1 to battery.

WARNING: Ensure all personnel are

standing at least 15 metres away from

module.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

PRECAUTIONS

9. Press both operating buttons to deploy airbag

module.

10. DO NOT return to airbag module for 30 minutes.

11. Using gloves and face mask, remove airbag

module from tool, place airbag module in plastic

bag and seal bag.

12. Wipe down tool with damp cloth.

13. Transport deployed airbag module to designated

area for incineration

NOTE: DO NOT transport airbag module in

the vehicle passenger compartment.

Passenger’s airbag module

1. Carry out deployment tool self test.

2. Remove airbag module from fascia.

See

Repair.

3. Position tool SMD 4082/6 in vice, ensuring that

vice jaws grip tool above bottom flange to

prevent possibility of tool being forced upwards

from vice. Tighten vice.

4. Position brackets SMD 4082/7 to tool; lightly

tighten bolts.

5. Secure airbag module to tool SMD 4082/6.

Ensure module is correctly secured using all

fixings.

SUPPLEMENTARY RESTRAINT SYSTEM

PRECAUTIONS

6. Ensure airbag module mounting brackets are

secure.

WARNING: Ensure tool SMD 4082/1 is not

connected to battery.

7. Connect flylead SMD 4082/5 to airbag module.

8. Connect flylead SMD 4082/5 to tool SMD

4082/1.

WARNING: Do not lean over module whilst

connecting.

9. Connect tool SMD 4082/1 to battery.

WARNING: Ensure all personnel are

standing at least 15 metres away from

module.

10. Press both operating buttons to deploy airbag

module.

11. DO NOT return to airbag module for 30 minutes.

12. Using gloves and face mask, remove airbag

module from tool, place airbag module in plastic

bag and seal bag.

13. Wipe down tool with damp cloth.

14. Transport deployed airbag module to designated

area for incineration

NOTE: DO NOT transport airbag module in

the vehicle passenger compartment.

SUPPLEMENTARY RESTRAINT SYSTEM

REPAIR

AIRBAG MODULE - PASSENGER SIDE

Service repair no - 76.73.69

WARNING: All the airbag system

components, including the wiring harness,

MUST be renewed after the airbags have

deployed.

Remove

1. Disconnect both battery terminals, disconnect

negative lead first.

2. Remove glove box assembly.

See CHASSIS

AND BODY, Repair.

3. Release and disconnect air bag module

multiplug.

4. Remove 4 bolts and washers (E-10 Torx Bit)

securing air bag module to fascia frame.

5. Carefully release and remove air bag module.

CAUTION: Store the airbag module

correctly.

See this section.

Refit

NOTE: If a new airbag module is being

fitted the serial numbers must be

recorded.

6. Carefully fit air bag module to fascia. Fit Torx

bolts, and washers.

7. Tighten bolts to

9 Nm. (7 lbf.ft)

8. Connect air bag module multiplug and secure to

location.

9. Fit glove box assembly.

See CHASSIS AND

BODY, Repair.

10. Connect battery terminals, fit battery cover and

secure with turnbuckles.

11. Check Supplementary Restraint System using

TestBook .

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

REPAIR

SRS ECU

Service repair no - 76.73.72

Remove

WARNING: Always disconnect negative

lead from battery first. Disconnection of

positive lead with negative lead connected

risks short circuit and severe sparking through

accidental grounding of spanner. Personal injury

could result.

1. Disconnect both battery terminals.

2. Remove centre console.

See CHASSIS AND

BODY, Repair.

3. Lift rear of sound deadener pad from

transmission tunnel.

4. Disconnect SRS ECU multiplug.

5. Release 2 multiplugs from bracket.

6. Remove 2 bolts securing ECU to bracket.

Remove ECU.

Refit

7. Reverse removal procedure.

SUPPLEMENTARY RESTRAINT SYSTEM

REPAIR

SRS HARNESS - SINGLE POINT SENSED SYSTEM

Service repair no - 76.73.73

The SRS harness is incorporated into the fascia

harness.

See ELECTRICAL, Repair.

SRS HARNESS - DISTRIBUTED SYSTEM

Service repair no - 76.73.73

Remove

1. Raise the vehicle.

WARNING: Support on safety stands.

2. Remove battery.

See ELECTRICAL, Repair.

3. Remove centre console.

See CHASSIS AND

BODY, Repair.

4. Remove passenger air bag module.

See this

section.

5. Remove radio.

See ELECTRICAL, Repair.

6. Remove instrument pack binnacle.

See

INSTRUMENTS, Repair.

7. Remove 5 screws securing switch pack to

fascia.

8. Disconnect switches, clock and temperature

sensor. Remove switch pack.

9. Remove 4 screws securing heater control panel.

10. Disconnect multiplugs. Remove control panel.

11. Release door aperture seal adjacent to A post

lower trim panels.

12. Driver’s side - LHD automatic vehicles only:

Remove 3 bolts securing foot rest. Remove foot

rest.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

REPAIR

13. Remove screw securing each A post lower trim

panel. Release panels from sprag clips. Remove

both trim panels.

14. Remove 4 scrivet fasteners securing drivers side

lower closing panel.

15. Disconnect footwell lamp multiplug. Remove

closing panel.

16. Disconnect SRS harness from main harness.

Release multiplug from clip.

17. Remove sound deadener pad from transmission

tunnel.

18. Disconnect multiplug from SRS ECU. Release 3

harness clips.

19. Remove both front wheel arch liners.

See

CHASSIS AND BODY, Repair.

SUPPLEMENTARY RESTRAINT SYSTEM

REPAIR

20. Remove 2 trim studs securing air cleaner baffle

beneath LH wheel arch. Remove baffle.

21. Disconnect both SRS crash sensor multiplugs.

22. Remove 4 bolts securing battery tray.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

REPAIR

23. Remove 2 bolts securing air cleaner to valance.

24. Raise air cleaner and battery tray to gain access

to crash sensor harness clips.

25. Release clips securing each crash sensor

harness to valance.

26. Release harness grommets. Feed both

harnesses through valance into wheel arches.

27. Release 3 clips securing each crash sensor

harness to underside of wheel arches.

28. Release harness bulkhead grommets. Feed

harnesses through bulkhead into passenger

compartment.

29. Disconnect SRS multiplug from instrument pack.

SUPPLEMENTARY RESTRAINT SYSTEM

REPAIR

30. Disconnect drivers air bag module connector.

Release connector and harness from clips.

31. Release 13 clips securing SRS harness to fascia

frame.

NOTE: Due to restricted access, two outer

clips ’A’ securing harness above heater

unit may have to be cut. Ensure that

location holes are clear. Collect loose ends of

clips.

32. Release 3 clips securing fascia harness trunking

to passenger side fascia frame.

33. Remove nut securing lower end of each blower

assembly to fascia frame.

34. Route crash sensor ends of harness into

passenger air bag module space.

35. Feed SRS ECU connector into passenger air

bag module space.

36. Remove harness.

Refit

37. Position harness in passenger air bag module

space. Feed SRS ECU connector between

heater and fascia frame.

38. Route harness along transmission tunnel.

Secure harness clips.

39. Connect multiplug to ECU.

40. Fit sound deadener pad to transmission tunnel.

41. Route crash sensor ends of harness correctly

around fascia frame and behind blower

assemblies.

42. Secure harness clips to fascia frame.

43. Position fascia harness trunking. Secure with

clips.

44. Secure blower assemblies to fascia frame with

nuts.

45. Connect drivers air bag module, secure

multiplug and harness to trunking.

46. Connect SRS multiplug to instrument pack.

SUPPLEMENTARY RESTRAINT SYSTEM NEW RANGE ROVER

REPAIR

47. Route SRS crash sensor harnesses through

bulkhead into wheel arches, locate harness

grommets.

48. Secure harness clips beneath wheel arches.

49. Route harnesses through valances into engine

bay. Locate harness grommets.

50. Raise battery tray and air cleaner for access.

Route crash sensor harnesses. Secure harness

clips.

51. Connect multiplugs to crash sensors.

52. Secure battery tray and air cleaner with bolts.

53. Connect SRS harness multiplug to main

harness. Secure multiplug to bracket.

54. Fit air cleaner baffle beneath LH wheel arch.

Secure with trim studs.

55. Fit wheel arch liners.

See CHASSIS AND

BODY, Repair.

56. Position drivers side lower closing panel.

Connect footwell lamp multiplug.

57. Align closing panel. Secure with scrivet

fasteners.

58. Position ’A’ post lower trim panels. Engage

sprag clips. Secure with screws.

59. Re-fit door aperture seals.

60. LHD automatic vehicles only: Position foot

rest. Secure with bolts.

61. Position heater controls. Connect multiplugs.

Secure to fascia with screws.

62. Position fascia switch pack. Connect multiplugs.

Secure to fascia with screws.

63. Fit instrument pack binnacle.

See

INSTRUMENTS, Repair.

64. Fit radio.

See ELECTRICAL, Repair.

65. Fit passenger air bag module.

See this section.

66. Fit centre console.

See CHASSIS AND BODY,

Repair.

67. Fit battery.

See ELECTRICAL, Repair.

68. Remove safety stands. Lower vehicle.

SRS CRASH SENSOR

Service repair no - 76.73.70

Remove

WARNING: Always disconnect negative

lead from battery first. Disconnection of

positive lead with negative lead connected

risks short circuit and severe sparking through

accidental grounding of spanner. Personal injury

could result.

1. Disconnect both battery terminals.

2. Disconnect sensor multiplug.

3. Remove 2 bolts securing sensor to valance.

Remove sensor.

Refit

4. Reverse removal procedure.

SUPPLEMENTARY RESTRAINT SYSTEM

REPAIR

AIRBAG MODULE - DRIVER SIDE

Service repair no - 76.73.71

Remove

1. Disconnect both battery terminals, negative lead

first.

2. Remove steering column nacelle.

See

STEERING, Repair.

3. Disconnect Supplementary Restraint System

(SRS) ’shorting link’.

4. Unscrew 4 bolts (TX 30 Torx bit) securing

module to steering wheel.

NOTE: Fixings remain captive in steering

wheel.

NOTE: Rotate steering wheel for access to

all fixings.

5. Release module from steering wheel, disconnect

multiplug.

6. Remove module.

CAUTION: Store the airbag module

correctly.

See Description and operation.

Refit

NOTE: If a new airbag module is being

fitted, the serial numbers must be

recorded.

7. Position module and connect multiplug.

8. Tighten bolts to

9 Nm. (7 lbf.ft)

9. Connect SRS ’shorting link’and secure

connector to location.

10. Fit steering column nacelle.

See STEERING,

Repair.

11. Connect battery terminals, positive before

negative. Fit and secure battery cover.

12. Check SRS using TestBook .

CHASSIS AND BODY

ADJUSTMENT

FRONT DOOR

Service repair no - 76.28.07

NOTE: Adjustment should not be

necessary unless door or hinges have

been renewed.

Alignment of door to aperture.

1. Gain access to ’A’ post hinge bolts by removing

relevant wheel arch liner.

See Repair.

2. Slacken 2 bolts securing striker to ’B/C’ post.

3. Slacken 6 bolts securing door hinges to ’A’ post.

4. With assistance, adjust door position in aperture.

Tighten hinge bolts to

30 Nm. (22 lbf.ft)

Profile adjustment, door skin/frame to adjacent

body panels.

5. Slacken 4 bolts securing hinges to door.

6. With assistance adjust inboard/outboard position

of door. Tighten hinge bolts to

30 Nm. (22 lbf.ft)

CAUTION: Ensure that leading edge of

door is flush with adjacent panels or wind

noise will result.

7. When alignment of door is correct, adjust height

and inboard/outboard position of striker. Tighten

striker bolts. Check for correct door latching.

8. Slacken bolts and readjust striker position as

necessary. Tighten striker bolts to

22 Nm. (16

lbf.ft)

9. Fit wheel arch liner.

See Repair.

REAR DOOR

Service repair no - 76.28.08

NOTE: Adjustment should not be

necessary unless door or hinges have

been renewed.

1. Open door and slacken 2 bolts securing striker

to ’D’ post.

2. Open front door and slacken 6 bolts securing

rear door hinges to ’B/C’ post.

3. With assistance, adjust door position in aperture

and tighten hinge bolts to

25 Nm. (18 lbf.ft)

4. To adjust profile of door skin and frame relative

to adjacent body panels, slacken 4 bolts

securing hingess to door.

5. With assistance adjust inboard/outboard position

of door. Tighten hinge bolts to

25 Nm. (18 lbf.ft)

CAUTION: Ensure that leading edge of

door is flush with adjacent panels or wind

noise will result.

6. When alignment of door is correct, adjust height

and inboard/outboard position of striker. Tighten

striker bolts and check for correct door latching.

7. Slacken bolts and readjust striker position as

necessary. Tighten striker bolts to

22 Nm. (16

lbf.ft)

CHASSIS AND BODY

REPAIR

BONNET

Service repair no - 76.16.01

Remove

1. Open bonnet.

2. Mark hinge outlines on bonnet.

3. Remove 2 hinge bolts from each side.

4. Disconnect washer tube at T piece on bonnet,

release tube from clip.

5. With assistance, release bonnet support struts at

lower ends.

6. With assistance, remove 2 remaining hinge bolts

and remove bonnet.

Refit

7. With assistance, fit bonnet. Fit, but do not tighten

bolts.

8. With assistance, connect bonnet support struts.

9. Connect washer tube, secure to clip.

10. Close bonnet, check alignment.

11. Open bonnet, tighten hinge bolts.

12. Close bonnet.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

BONNET LOCK PIN

Service repair no - 76.16.24

Remove

1. Remove bolts securing lock pin to bonnet.

2. Remove pin.

Refit

3. Position lock pin to bonnet.

4. Fit bolts but do not tighten.

5. Close and open bonnet to align pin.

6. Secure pin with bolts.

7. Lubricate pin.

BONNET LOCK - LEFT HAND

Service repair no - 76.16.21

Remove

1. Remove bolts securing bonnet lock.

2. Release outer and inner cables from lock.

3. Remove lock.

Refit

4. Reverse removal procedure.

CHASSIS AND BODY

REPAIR

BONNET LOCK - RIGHT HAND

Service repair no - 76.16.25

Remove

1. Release 3 turnbuckles securing battery cover.

Remove cover

2. Remove 2 bolts securing bonnet lock to platform.

3. Manoeuvre lock and disconnect alarm switch

multiplug.

4. Release inner and outer cables from lock.

5. Remove lock.

Refit

6. Reverse removal procedure.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

BONNET SAFETY CATCH

Service repair no - 76.16.34

Remove

1. Remove bolts securing safety catch to bonnet.

2. Remove safety catch.

Refit

3. Position catch to bonnet.

4. Fit bolts, do not tighten.

5. Close and open bonnet to align catch.

6. Secure catch with bolts.

BONNET STRUT

Service repair no - 76.16.14

Remove

1. Support bonnet in open position.

2. Release clip securing strut lower ball joint.

3. Remove screws securing strut bracket to bonnet.

4. Remove strut and bracket.

5. Remove strut from bracket.

Refit

6. Fit strut to bonnet bracket, fit to bonnet.

7. Secure strut to lower ball joint.

8. Fit bracket screws. Remove support, close

bonnet.

CHASSIS AND BODY

REPAIR

CENTRE CONSOLE

Service repair no - 76.25.01

Remove

1. Remove electric window switch pack.

See

ELECTRICAL, Repair.

2. Disconnect rear footwell lamp multiplug.

3. Remove base in console bin.

4. Remove nuts securing rear of console to floor

studs.

5. Move both front seats fully rearward.

6. Remove 2 screws securing each side panel to

centre console. Release sprag clips from fascia

switch pack by firmly pulling rearwards. Remove

side panels.

7. Remove screw at rear of gear lever applique.

Raise rear end of applique to disengage 2 spring

clips at forward end.

8. Disconnect cigar lighter multiplug, release cigar

lighter bulb. Remove gear lever applique.

9. Manual gearbox models:

Remove gear knob. Remove 2 bolts securing

front of console to floor.

10. Automatic gearbox models:

Remove 2 screws securing selector lever.

11. Remove selector lever.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

12. Remove 3 screws securing selector graphics

plate.

13. Raise selector graphics plate, disconnect

multiplug.

14. Remove selector graphics plate.

15. All models:

Remove clip securing park brake lever clevis pin,

remove clevis pin. Raise park brake lever to

vertical position.

16. Raise rear of console to disengage rear vent

ducts. Remove centre console.

Refit

17. Fit centre console, ensuring that ducts to rear

fresh air vents are correctly engaged.

18. Fit nuts securing centre console to floor.

19. Automatic - position graphics plate over selector

lever, connect multiplug.

20. Align graphics plate to console, secure with

screws.

21. Fit selector lever, secure with screws.

22. Manual - secure front of centre console to floor

with bolts.

23. Fit gear knob.

24. Lower park brake lever, fit clevis pin and secure

pin with clip.

25. Position gear/selector lever applique, connect

cigar lighter multiplug and insert illumination bulb

in holder.

26. Engage applique clips to console. Secure

applique with screw.

27. Position console side panels. Firmly push

forward to engage sprag clips into fascia switch

pack. Fit and tighten screws.

28. Return front seats to original positions.

29. Fit base to console bin, tighten with screws.

30. Connect rear footwell lamp multiplug.

31. Fit electric window switch pack.

See

ELECTRICAL, Repair.

CHASSIS AND BODY

REPAIR

CHASSIS CROSS MEMBER

Remove

1. Disconnect battery negative lead.

2. Raise vehicle on four post lift.

3. Support transmission with a suitable stand.

4. Remove and discard 6 nuts securing

transmission mount to crossmember. Remove

snubber bar.

5. Remove 3 of 4 nuts and bolts securing each side

of crossmember to chassis.

6. With assistance, remove remaining bolt securing

crossmember. Remove crossmember.

Refit

7. With assistance, position crossmember to

chassis. Secure with nuts and bolts. Tighten to

45 Nm. (33 lbf.ft)

8. Fit snubber bar. Secure transmission mount to

crossmember with new flange nuts. Tighten to

45 Nm. (33 lbf.ft)

9. Remove support from transmission.

10. Lower vehicle.

11. Reconnect battery negative lead.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

ENGINE ACOUSTIC COVER

Service repair no - 76.11.06

Remove

1. Raise front of vehicle.

WARNING: Support on safety stands.

2. Release 4 threaded fasteners securing engine

acoustic cover to chassis brackets.

3. Release acoustic cover from brackets and

manoeuvre past steering gear.

Refit

4. Fit acoustic cover to brackets and secure with

threaded fasteners.

GEARBOX LOWER ACOUSTIC COVER

Service repair no - 76.11.13

Remove

1. Raise front of vehicle.

WARNING: Support on safety stands.

2. Release 6 threaded fasteners securing lower

acoustic cover to side acoustic covers.

3. Remove lower acoustic cover.

Refit

4. Fit acoustic cover to side acoustic covers.

5. Tighten threaded fasteners securing lower cover

to side covers.

6. Remove stand(s) and lower vehicle.

CHASSIS AND BODY

REPAIR

GEARBOX ACOUSTIC COVER - RH

Service repair no - 76.11.14

Remove

1. Raise front of vehicle.

WARNING: Support on safety stands.

2. Remove gearbox lower acoustic cover.

See this

section.

3. Remove bolt securing RH acoustic cover to

crossmember.

4. Remove bolt securing RH acoustic cover to

chassis member.

5. Remove gearbox RH acoustic cover.

Refit

6. Fit acoustic cover to chassis and secure with

bolts.

7. Fit gearbox lower acoustic cover.

See this

section.

GEARBOX ACOUSTIC COVER - LH

Service repair no - 76.11.15

Remove

1. Raise front of vehicle.

WARNING: Support on safety stands.

2. Remove gearbox lower acoustic cover.

See this

section.

3. Remove bolt securing LH acoustic cover to

crossmember.

4. Remove bolt securing LH acoustic cover to

chassis member.

5. Remove gearbox LH acoustic cover.

Refit

6. Fit acoustic cover to chassis and secure with

bolts.

7. Fit gearbox lower acoustic cover.

See this

section.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

FRONT BUMPER VALANCE

Service repair no - 76.22.72

Remove

1. Raise the vehicle.

WARNING: Support on safety stands.

2. Remove battery cover for access to RH fog

lamp.

3. Disconnect fog lamp multiplugs and breather

hoses.

4. Release 2 clips securing bumper ends to

mounting brackets.

CAUTION: Loosen bolts securing bumper

end mounting brackets to chassis frame to

avoid damage to sealing rubber during

bumper remove and refit.

CHASSIS AND BODY

REPAIR

5. Remove 2 bumper bolt access plugs from

bumper valance. Remove bolts.

6. With assistance remove bumper assembly.

not carry out further dismantling if

component is removed for access only.

7. Remove 8 studs and 6 clips securing extensions

spoiler. Remove extension.

8. Remove 8 screws securing fog lamps. Remove

lamps.

9. Remove 8 bolts securing bumper end brackets

to bumper. Remove brackets.

WARNING: If front bumper is damaged due

to impact, the impact cans must be

inspected. There must be no visible

deformation. The overall length must be 188.25

mm æ 0.5 mm. Replace the impact cans if

necessary.

Refit

10. Fit end brackets and secure with bolts. Fit fog

lamps and secure with screws.

11. Fit extension and secure with clips and studs.

12. With assistance fit bumper assembly, tighten

bolts to

70Nm. (52 lbf.ft)

13. Fit bolt access plugs.

14. Align end brackets, tighten bolts and secure

bumper end clips.

15. Connect fog lamp multiplugs and breather

hoses, fit battery cover.

16. Remove safety stands. Lower vehicle.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

EXTENSION SPOILER FRONT BUMPER

Service repair no - 76.22.78

Remove

1. Raise the vehicle.

WARNING: Support on safety stands.

2. Remove 8 studs and 6 clips securing spoiler to

front bumper.

3. Remove spoiler halves.

Refit

4. Fit spoiler halves to bumper. Secure with clips

and studs.

5. Remove safety stands. Lower vehicle.

REAR BUMPER VALANCE

Service repair no - 76.22.74

Remove

1. Raise the vehicle.

WARNING: Support on safety stands.

2. Remove rear road wheels.

3. Remove 3 screws securing each mud flap.

Remove mud flaps.

4. Remove 2 screws securing each wheel arch

liner extension panel to rear bumper/chassis.

5. Remove 2 wheel arch liner extension panels.

6. Release 2 clips securing bumper ends to

mounting brackets.

CHASSIS AND BODY

REPAIR

7. Disconnect 3 towing harness multiplugs.

8. Remove 2 mounting bolt covers.

9. Remove 2 bolts securing bumper to chassis.

10. With assistance, release bumper ends from

brackets. Remove bumper.

Refit

11. With assistance, position bumper. Engage nylon

end supports to brackets.

12. If necessary, slacken bolts securing end support

brackets. Align bumper to body. Tighten to

Nm. (22 lbf.ft)

13. Fit bumper mounting bolts. Tighten to

70 Nm.

(52 lbf.ft)

14. Fit bolt covers.

15. Secure bumper end clips.

16. Connect towing harness multiplugs.

17. Position wheel arch liner extensions. Secure with

screws.

18. Position mud flaps. Secure with screws.

19. Fit road wheels. Tighten to

108 Nm. (80 lbf.ft)

20. Remove safety stands. Lower vehicle.

FASCIA ASSEMBLY

Service repair no - 76.46.23/99

WARNING: The fascia assembly houses

the heater distribution unit, blower

assemblies and air conditioning

evaporator. Assistance is essential during

removal and refit procedures.

CAUTION: When removed from the

vehicle, the fascia should be placed on a

soft covered work surface, supported on

suitable wooden blocks.

Remove

1. Vehicles with SRS only: Remove battery.

See

ELECTRICAL, Repair.

2. Vehicles without SRS: Disconnect battery

negative lead.

3. Drain cooling system.

See COOLING SYSTEM,

Repair.

4. Loosen hose clips, disconnect hoses from

heater pipes.

5. Remove centre console.

See this section.

6. Remove steering column.

See STEERING,

Repair.

7. Remove wiper motor and linkage.

See WIPERS

AND WASHERS, Repair.

8. Disconnect passenger side heated front screen

multiplug. Release multiplug from clip.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

9. Remove 6 bolts, remove remaining scuttle side

panel.

10. Remove heater intake pollen filters.

11. Remove 8 screws securing each pollen filter

housing. Remove both housings.

12. Remove radio.

See ELECTRICAL, Repair.

13. Release door aperture seal adjacent to ’A’ post

lower trim panels.

14. Driver’s side - LHD automatic vehicles only:

Remove 3 bolts securing foot rest through ’A’

post lower trim, remove foot rest.

15. Remove screw securing each ’A’ post lower trim

panel, release from single sprag clip, remove

both trim panels.

CHASSIS AND BODY

REPAIR

16. Remove fuse cover from driver’s seat base trim.

17. Remove screw and 2 trim studs, remove seat

base trim.

18. Release 4 sprag clips, remove driver’s side

carpet retainer.

19. Remove 2 scrivet fasteners securing lower

closing panel to passenger side of fascia.

20. Release closing panel, disconnect footwell lamp,

release diagnostic multiplug. Remove closing

panel.

21. Remove 4 bolts, remove fascia centre bracket.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

22. Disconnect 4 multiplugs from Body Electrical

Control Module (BeCM)

23. Remove captive nut, remove earth wires from

stud at base of driver’s side ’A’ post.

24. Disconnect multiplugs at base of each ’A’ post.

25. Release BeCM harness from sill, route into

fascia to prevent fouling as fascia is removed.

26. Disconnect multiplugs and release vacuum hose

from brake and clutch switches.

27. Models with SRS only: Disconnect SRS

multiplug from main harness.

CHASSIS AND BODY

REPAIR

28. Disconnect multiplug from SRS control module,

route harness into fascia to prevent fouling as

fascia is removed.

29. Remove both front wheel arch liners.

See this

section.

30. Remove 2 scrivet fasteners securing air cleaner

baffle beneath LH wheel arch. Remove baffle.

31. Disconnect both SRS crash sensor multiplugs.

32. Remove 4 bolts securing battery tray and 2 bolts

securing air cleaner to valance.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

33. Raise air cleaner and battery tray for access to

crash sensor harness clips.

34. Release clips securing each crash sensor

harness to valance. Release harness grommets

and feed both harnesses through valance into

wheel arches.

35. Release 3 clips securing each crash sensor

harness to underside of wheel arches.

36. Release harness grommets, feed harnesses

through bulkhead and route into fascia to

prevent fouling as fascia is removed.

37. Vehicles with air conditioning only: Discharge

air conditioning system.

See AIR

CONDITIONING, Adjustment.

38. Remove bolt securing pipe clamp to

Thermostatic Expansion Valve (TXV).

39. Release pipes from TXV and remove ’O’ rings.

Seal pipes and ports of TXV.

40. All models: Remove 4 tube bolts securing

fascia to scuttle panel.

CHASSIS AND BODY

REPAIR

41. Remove nuts and washers securing fascia to

base of ’A’ posts.

42. Remove bolt securing fascia to pedal box.

43. Using assistance, carefully manoeuvre the

fascia through the driver’s door aperture. Place

fascia on a soft covered work surface, supported

on suitable wooden blocks.

44. Remove rubber seals from air intake ducts.

45. Collect rear heater duct connecting tubes.

Refit

46. Fit intake seals to blower motor ducts. Tape

rubbers inside blower ducts to aid fitment.

NOTE: Tape the rubbers at this stage, as

they are almost impossible to locate after

dash fitment.

47. Fit guide pins LRT-76-001 to outer fascia studs.

48. With assistance, manoeuvre fascia into position

through driver’s front door aperture. Locate

guide pins.

NOTE: Assistance from a third person may

be necessary when guiding heater pipes

through bulkead.

49. Loosely fit 1 tube bolt, fascia to scuttle.

50. Fit bolt securing fascia to pedal box. Tighten to

25 Nm. (18 lbf.ft)

51. Fit nuts and washers at base of A posts. Tighten

25 Nm. (18 lbf.ft)

52. Remove guide pins.

53. Fit remaining tube bolts. Tighten to

25 Nm. (18

lbf.ft)

54. Fit rear heater duct connecting pipes.

55. Remove tape from intake seals.

56. Engage lips of sealing rubbers around scuttle

apertures.

57. Fit pollen filter housings, tighten bolts.

58. Fit scuttle side panel to passenger side of

vehicle, tighten bolts.

59. Connect heated screen multiplug, fit to side

panel clip.

60. Connect hoses to heater pipes. Tighten clips.

61. Air conditioning vehicles: Remove seals from

air conditioning pipes and TXV ports.

62. Lubricate new O rings with clean compressor oil,

fit to pipes.

63. Locate pipes in TXV ports, position clamp and fit

clamp bolt.

64. Engage evaporator drain tubes over pipes in

transmission tunnel.

65. Vehicles with SRS only: Route SRS crash

sensor harnesses through bulkhead into wheel

arches, locate harness grommets.

66. Secure harness clips beneath wheel arches,

route harnesses through valances into engine

bay, locate harness grommets.

67. Raise battery tray and air cleaner for access.

Route crash sensor harnesses, secure harness

clips, connect multiplugs to crash sensors.

68. Tighten battery tray and air cleaner bolts.

69. Connect multiplug to SRS control module.

70. Connect SRS harness multiplug to main

harness.

71. Fit air cleaner baffle beneath LH wheel arch,

secure with scrivet fasteners.

72. Fit wheel arch liners.

See this section.

73. All models:Route harness along sill, connect

multiplugs to BeCM.

74. Connect multiplugs at base of ’A’ posts and

secure plugs to brackets.

75. Fit earth wires to stud, tighten captive nut.

76. Connect vacuum hose and multiplugs to brake

and clutch pedal switches.

77. Position closing panel beneath passenger side

of fascia. Secure dianostic plug, connect footwell

lamp. Align closing panel, secure with scrivet

fasteners.

78. Fit carpet retainer, engage sprag clips.

79. Fit seat base trim panel, secure trim studs,

tighten screw.

80. Fit fuse cover to seat base trim.

81. Fit both ’A’ post lower trim panels, secure sprag

clips. Engage door aperture seals.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

82. LHD automatic vehicles only: Fit foot rest,

secure with bolts.

83. Fit radio.

See ELECTRICAL, Repair.

84. Fit wiper motor and linkage.

See WIPERS AND

WASHERS, Repair.

85. Fit steering column.

See STEERING, Repair.

86. Fit centre console.

See this section.

87. Refill cooling system.

See COOLING SYSTEM,

Repair.

88. Vehicles with SRS only: Fit battery.

See

ELECTRICAL, Repair.

89. Reconnect battery negative lead.

90. Evacuate and recharge air conditioning.

See

AIR CONDITIONING, Adjustment.

FASCIA ASSEMBLY - VEHICLES WITH SINGLE

POINT SENSED SRS

Service repair no - 76.46.23/99

WARNING: Refer to SRS safety

precautions before commencing repair.

WARNING: The fascia assembly houses

the heater distribution unit, blower

assemblies and air conditioning

evaporator and is therefore heavy. Assistance is

essential during removal and refit procedures.

CAUTION: When removed from the

vehicle, the fascia should be placed on a

work surface with a soft covering and

supported on suitable wooden blocks.

Remove

1. Remove key from starter switch and wait 10

minutes for SRS back up power circuit to

discharge.

2. Disconnect both battery terminals, earth lead

first.

3. Drain cooling system.

See COOLING SYSTEM,

Repair.

4. Release 2 clips securing heater hoses to heater

matrix and disconnect hoses.

5. Cap both heater matrix pipes to prevent coolant

spillage inside vehicle during fascia removal.

6. Recover refrigerant from air conditioning system.

See AIR CONDITIONING, Adjustment.

CHASSIS AND BODY

REPAIR

7. Remove bolt securing pipe clamp to thermostatic

expansion valve (TXV) and release pipes.

8. Remove and discard ’O’ ring seals from air

conditioning pipes.

9. Immediately cap both air conditioning pipes and

TXV ports to prevent moisture entering the air

conditioning system.

10. Remove wiper motor and linkage.

See WIPERS

AND WASHERS, Repair.

11. Disconnect passenger side heated screen

multiplug.

12. Release heated screen multiplug from scuttle

side panel and position aside.

13. Remove 6 bolts securing scuttle side panel to

scuttle and remove panel.

14. Remove pollen filter from both heater intake

housings.

15. Remove 8 screws securing each heater intake

housing to scuttle and remove intake housings.

Release sealing rubbers from scuttle panel

aperture.

16. Remove centre console.

See this section.

17. Remove transmission tunnel insulation pad.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

18. Release latching mechanism and disconnect

multiplug from airbag diagnostic and control unit

(DCU).

19. Release SRS harness from transmission tunnel

and position to fascia to avoid snagging.

20. Remove 6 nuts securing gear lever gaiter ring to

transmission tunnel and release gaiter.

21. Remove 2 bolts securing gear lever to gearbox

remote and remove gear lever.

22. Disconnect high/low switch multiplug.

23. Remove 4 bolts securing fascia centre bracket to

fascia and transmission tunnel.

24. Remove fascia centre bracket.

25. Remove radio.

See ELECTRICAL, Repair.

26. Remove steering column.

See STEERING,

Repair.

CHASSIS AND BODY

REPAIR

27. Remove 3 scrivets securing lower fascia closing

panel to passenger’s side of fascia.

28. Release closing panel and release diagnostic

connector from panel.

29. Release door aperture seal adjacent to ’A’ post

lower trim panels.

30. Remove screw securing each ’A’ post lower trim

panel to ’A’ post.

31. Release ’A’ post lower trim panels from sprag

clip and remove panels.

32. Remove fuse box cover from driver’s seat base

trim.

33. Remove screw and 3 trim studs securing seat

base trim to body and remove seat base trim.

34. Release 4 sprag clips securing driver’s side

carpet retainer to body and remove carpet

retainer.

35. Disconnect 3 multiplugs from Body Electrical

Control Module (BeCM).

36. Position carpet aside and disconnect multiplug

from rear of BeCM.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

37. Remove captive nut securing earth wires to

driver’s side lower ’A’ post and release 3

additional earth wires.

38. Disconnect 3 multiplugs at base of driver’s side

’A’ post.

39. Release harness from driver’s side carpet and

position to fascia to avoid snagging.

40. Disconnect multiplugs from clutch and 2 brake

pedal switches.

41. Disconnect vacuum hose from clutch and brake

pedal switches.

42. Disconnect 2 multiplugs at base of passenger’s

side ’A’ post.

43. Remove 2 nuts securing fascia to ’A’ post and

transmission tunnel bracket, passenger’s side

44. Remove 2 nuts securing fascia to ’A’ post and

transmission tunnel bracket, driver’s side.

CHASSIS AND BODY

REPAIR

45. Remove 4 tube bolts securing fascia assembly

to scuttle panel.

46. Disconnect 2 evaporator drain hoses from

evaporator.

47. Using assistance, carefully manoeuvre fascia

assembly through the driver’s door aperture.

Position the fascia on a work surface with a soft

covering and support on suitable wooden blocks.

48. Collect 2 ducts connecting rear heating pipes to

fascia assembly.

Refit

49. Tape intake duct seals inside blower duct to aid

fitment.

50. Fit guide pins LRT-76-001 to outer fascia studs.

51. With assistance, manoeuvre fascia assembly

through driver’s door aperture and locate guide

pins to scuttle panel.

NOTE: Assistance from a third person may

be required to guide heater pipes through

bulkhead.

52. Fit one tube bolt securing fascia to scuttle panel

but do not tighten.

53. Fit nuts securing fascia to lower ’A’ posts and

tighten to

25 Nm. (18 lbf.ft)

54. Fit nuts securing fascia to transmission tunnel

brackets and tighten to

25 Nm. (18 lbf.ft)

55. Remove LRT-76-001.

56. Fit remaining tube bolts securing fascia to scuttle

panel and tighten to

25 Nm. (18 lbf.ft)

57. Fit fascia centre bracket, fit bolts and tighten to

25 Nm. (18 lbf.ft)

58. Connect evaporator drain hoses to evaporator.

59. Fit ducts connecting rear heating pipes to fascia

assembly.

60. Fit gearlever to gearbox remote, fit bolts and

tighten to

25 Nm. (18 lbf.ft)

61. Fit gear lever gaiter and ring to transmission

tunnel and secure with nuts.

62. Connect high/low switch multiplug.

63. Position SRS harness to transmission tunnel.

64. Connect multiplug to airbag DCU. Ensure

connector latching mechanism is correctly

engaged.

65. Fit transmission tunnel insulation pad to

transmission tunnel and position multiplugs

through pad.

66. Fit radio.

See ELECTRICAL, Repair.

67. Connect multiplugs at base of passenger’s side

’A’ post.

68. Fit passenger’s side ’A’ post lower trim panel

and secure with screw.

69. Engage door aperture seal to door aperture.

70. Position fascia lower closing panel and engage

diagnostic connector to panel.

71. Position closing panel to fascia and secure with

scrivets.

72. Connect vacuum hose to clutch and brake pedal

switches.

73. Connect multiplugs to clutch and brake pedal

switches.

74. Position harness to driver’s side carpet.

75. Connect multiplugs to BeCM.

76. Connect multiplugs at base to driver’s side ’A’

post.

77. Position earth wires to ’A’ post stud, fit and

secure captive nut.

78. Fit driver’s side carpet retainer and engage to

clips.

79. Fit seat base trim and secure with trim studs and

screw.

80. Fit seat base fuse box cover.

81. Fit driver’s side lower ’A’ post trim and secure

with screw.

82. Fit steering column.

See STEERING, Repair.

83. Fit radio.

See ELECTRICAL, Repair.

84. Fit centre console.

See this section.

85. Remove tape from heater intake ducts.

86. Engage heater intake seals to scuttle apertures.

87. Fit heater intake housings and secure with

screws.

88. Fit pollen filters to intake housings.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

89. Fit wiper motor and linkage.

See WIPERS AND

WASHERS, Repair.

90. Fit scuttle side panel to scuttle and secure with

bolts.

91. Connect heated screen multiplug and engage

multiplug to scuttle side panel bracket.

92. Remove caps from heater matrix pipes.

93. Engage heater matrix grommet to bulkhead

aperture.

94. Connect heater hoses to heater matrix and

secure with clips.

95. Remove caps from air conditioning pipes and

TXV.

96. Lubricate NEW ’O’ ring seals with clean

compressor oil and fit to air conditioning pipes.

97. Connect air conditioning pipes to TXV, position

clamp and fit bolt.

98. Tighten clamp bolt to

6 Nm. (4 lbf.ft)

99. Charge air conditioning system.

See AIR

CONDITIONING, Adjustment.

100. Fill coolant system.

See COOLING SYSTEM,

Repair.

101. Connect both battery terminals, earth lead last.

FASCIA CLOSING PANEL

Service repair no - 76.46.27

Remove

1. Remove closing panel screw covers and screws.

2. Lower closing panel.

3. Disconnect air tube from closing panel, remove

panel.

Refit

4. Reverse removal procedure.

CHASSIS AND BODY

REPAIR

FRONT DOOR ASSEMBLY

Service repair no - 76.28.01/99

Remove

1. Release door harness protective sleeve from ’A’

post.

2. Disconnect door harness multiplugs.

3. Remove door check strap retaining pin.

CAUTION: Apply protective tape to ’A’

post before drifting out retaining pin.

4. Remove door hinge pin retaining clips.

5. With assistance, remove door assembly.

Refit

6. With assistance, position door on hinges. Fit

retaining clips.

7. Align door check strap. Fit retaining pin.

8. Remove protective tape from ’A’ post.

9. Connect harness multiplugs. Secure protective

sleeve to ’A’ post.

10. If necessary adjust door.

See Adjustment.

GLASS - FRONT DOOR

Service repair no - 76.31.01

Remove

1. Remove front door outer waist seal.

See this

section.

2. Remove front door plastic sheet.

See this

section.

3. Turn ignition ON.

4. Lower glass approximately 120mm (5 in.)

Remove rear regulator arm retaining clip.

5. Lower glass to align forward clip with the

regulator plate lower retaining rivet. Turn ignition

OFF.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

6. Remove front lower fixing clip.

7. Remove nut securing bracket to vertical slide.

8. Release bracket from slide.

CAUTION: Chock glass with wooden

block, or retain with tape, to prevent glass

dropping when regulator arms are

released.

9. Using a suitable lever, release 2 regulator arms

from glass lower fixings.

10. Support weight of glass. Remove wooden chock

or tape.

11. Rotate glass anti-clockwise to release from

runners.

12. Remove front door glass.

Refit

13. Refit front door glass.

14. Rotate glass anti-clockwise, fit to runners.

15. Secure glass fixings to regulator arms.

16. Position glass bracket to vertical runner, fit

retaining nut.

17. Fit clip securing regulator arm to glass runner.

18. Turn ignition ON.

19. Raise door glass approximately 120mm (5 in.)

Fit rear glass retaining clip.

20. Raise door glass.

21. Turn ignition OFF.

22. Fit front door plastic sheet.

See this section.

23. Fit front door outer waist seal.

See this section.

CHASSIS AND BODY

REPAIR

GLASS REGULATOR - FRONT DOOR

Service repair no - 76.31.45

Remove

1. Remove front door glass.

See this section.

2. Disconnect window lift motor harness connector.

3. Remove rivet securing regulator runner to door

panel.

4. Remove 3 rivets.

5. Remove regulator assembly.

Refit

6. Reverse removal procedure.

LATCH - FRONT DOOR

Service repair no - 76.37.12

Remove

1. Remove front door trim casing.

See this

section.

2. Release rear of plastic sheet.

3. Release retaining clip, private lock to latch

operating rod, at latch end.

4. Release control rod from latch.

5. Release retaining clip, outside handle to latch

operating rod, at latch end.

6. Release control rod from latch.

7. Disconnect 2 latch motor multiplugs.

8. Remove door sill button from operating rod.

9. Release remote handle to latch operating cable

from clip.

10. Remove 3 screws securing latch.

11. Release latch from door.

12. Remove sill button operating rod from latch.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

13. Release outer operating cable from latch

abutment.

14. Release inner cable from latch.

15. Remove latch from door.

Refit

16. Fit latch.

17. Fit inner operating cable to latch.

18. Fit outer operating cable to latch abutment.

19. Fit sill button operating rod to latch.

20. Align latch to door, tighten 3 screws.

21. Secure remote handle cable to door panel clip.

22. Fit sill button to operating rod.

23. Reconnect 2 latch motor multiplugs.

24. Fit outside handle operating rod to latch.

25. Fit retaining clip.

26. Fit private lock operating rod to latch.

27. Fit retaining clip.

28. Secure plastic sheet.

29. Fit front door trim casing.

See this section.

CHASSIS AND BODY

REPAIR

REMOTE CONTROL - FRONT DOOR

Service repair no - 76.37.31

Remove

1. Remove front door trim casing.

See this

section.

2. Release top rear corner of plastic sheet.

3. Pull remote handle out. Release inner cable from

remote handle.

4. Release remote handle.

5. Remove 2 screws securing remote handle.

6. Remove outer cable from housing.

7. Remove remote by sliding rearwards.

Refit

8. Reverse removal procedure.

OUTER WAIST SEAL - FRONT DOOR

Service repair no - 76.31.53

Remove

1. Remove screw securing rear edge of outer waist

seal.

2. Remove outer waist seal.

Refit

3. Reverse removal procedure.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

OUTSIDE HANDLE - FRONT DOOR

Service repair no - 76.58.07

Remove

1. Remove front door trim casing.

See this

section.

2. Release rear half of plastic sheet.

3. Remove retaining clip, private lock to latch

operating rod, at latch end.

4. Remove control rod from latch and private lock.

5. Remove retaining clip, outside handle to latch

operating rod, at latch end.

6. Remove control rod from latch and outside

handle.

7. Remove bolt securing rear of outside handle.

8. Slide outside handle forwards. Pull handle out,

release rear of handle from door.

CHASSIS AND BODY

REPAIR

9. Remove handle from front fixing by pivotting rear

end of handle out.

10. Remove gasket from handle.

11. Remove rubber locking plate from door.

12. Remove plastic locking plate from door.

13. Remove screw securing mounting plate to door,

remove plate.

Refit

14. Clean handle and door mating faces.

15. Reverse removal procedure.

PLASTIC SHEET - FRONT DOOR

Service repair no - 76.34.26

Remove

1. Remove front door trim casing.

See this

section.

2. Remove 2 screws securing door outstation ECU.

3. Remove 2 screws securing speaker amplifier.

4. Remove 4 screws securing front door speaker.

5. Release speaker, disconnect multiplug.

6. Remove plastic sheet.

Refit

7. Reverse removal procedure.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

PRIVATE LOCK - FRONT DOOR

Service repair no - 76.37.39

Remove

1. Remove outside handle.

See this section.

2. Fit door lock key.

3. Remove screw securing lock.

4. Remove cam and washer from lock.

5. Remove cam lock and stop from lock.

6. Remove cam return spring. Remove lock from

outside handle.

Refit

7. Apply grease to lock barrel.

8. Fit lock to outside handle.

9. Fit cam return spring, cam stop, cam lock,

washer and cam.

10. Fit screw securing lock to outside handle.

11. Remove door lock key.

12. Refit front door outside handle.

See this

section.

TRIM CASING - FRONT DOOR

Service repair no - 76.34.01

Remove

1. Release cheater panel.

2. Disconnect 2 tweeter speaker connectors,

remove cheater panel.

3. Remove screw securing remote handle

escutcheon, remove escutcheon.

4. Remove 3 screws securing trim casing.

5. Release 12 clips retaining trim casing.

CHASSIS AND BODY

REPAIR

6. Disconnect speaker connector.

7. Remove door trim casing.

Disassemble

8. Remove 12 trim casing retaining clips.

9. Remove 4 screws, remove speaker.

10. Remove 4 screws, remove speaker grille.

11. Remove 7 screws, remove trim casing pocket.

12. Remove 3 screws, remove arm rest.

13. Remove retaining clamp and sill button

escutcheon.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

14. Remove door trim casing waist seal.

Assemble

15. Fit door trim casing waist seal.

16. Fit sill button escutcheon, position retaining

clamp, tighten screw.

17. Fit arm rest to trim casing, tighten 3 screws.

18. Fit trim casing pocket, tighten 7 screws.

19. Fit speaker grille to trim casing, tighten 4 screws.

20. Fit speaker to trim, tighten 4 screws.

21. Fit 12 retaining clips.

Refit

22. Connect trim casing speaker connector.

23. Fit trim casing, locating 12 retaining clips.

24. Fit 3 screws securing trim casing.

25. Fit remote handle escutcheon, tighten screw.

26. Position cheater panel, connect 2 tweeter

speaker connectors.

27. Secure cheater panel.

INSERT CAPPING - FRONT DOOR

Service repair no - 76.34.32

Remove

1. Fit protection to door trim casing.

2. Position a blunt flat blade between trim casing

and insert upper edge.

3. Gently raise blade to remove insert.

4. Remove retaining clips from insert.

Refit

5. Fit insert to door casing. Secure with clips.

6. Remove protection from door casing.

CHASSIS AND BODY

REPAIR

REAR DOOR ASSEMBLY

Service repair no - 76.28.02/99

Remove

1. Release door harness protective sleeve from

’B/C’ post.

2. Disconnect door harness multiplugs.

3. Remove check strap retaining pin.

CAUTION: Apply protective tape to ’B/C’

post before drifting out pin.

4. Remove hinge pin retaining clips.

5. With assistance, remove door assembly.

Refit

6. With assistance fit door to hinges.

7. Fit hinge retaining clips.

8. Align check strap and fit retaining pin.

9. Remove protective tape.

10. Connect harness multiplugs, secure protective

sleeve to ’B/C’ post.

11. If necessary adjust door.

See Adjustment.

GLASS - REAR DOOR

Service repair no - 76.31.02

Remove

1. Remove outer waist seal.

See this section.

2. Remove door trim casing.

See this section.

3. Remove speaker and plastic sheet.

See this

section.

4. Remove window motor and control panel

assembly.

See ELECTRICAL, Repair.

5. Remove glass rear channel.

See this section.

6. Remove wedges or tape from glass.

7. Release glass from channel. Raise to remove

glass from door.

Refit

8. Fit glass to door and align to frame.

9. Wedge or use tape to hold glass in door.

10. Fit glass rear channel.

See this section.

11. Fit window motor and control panel.

See

ELECTRICAL, Repair.

12. Fit speaker and plastic sheet.

See this section.

13. Fit trim casing.

See this section.

14. Fit outer waist seal.

See this section.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

PLASTIC SHEET - REAR DOOR

Service repair no - 76.34.28

Remove

1. Remove rear door trim casing.

See this

section.

2. Remove speaker.

See ELECTRICAL, Repair.

3. Remove 2 screws securing amplifier to door.

4. Remove plastic sheet.

Refit

5. Reverse removal procedure.

OUTSIDE HANDLE - REAR DOOR

Service repair no - 76.58.02

Remove

1. Remove rear door trim casing.

See this

section.

2. Remove bolt securing handle.

3. Remove outside handle.

NOTE: Operate and pull handle outward,

pivotting at forward mounting point.

4. Remove gasket.

5. Remove locking plates.

6. Remove screw securing mounting plate, remove

plate.

CHASSIS AND BODY

REPAIR

Refit

7. Clean handle face on door.

8. Fit handle mounting plate, tighten screw.

9. Fit locking plates.

10. Fit gasket to handle, position handle, secure with

screw.

11. Refit door trim casing.

See this section.

LATCH - REAR DOOR

Service repair no - 76.37.13/70

Remove

1. Remove window lift motor/control unit assembly.

See ELECTRICAL, Repair.

2. Release door lock remote control cable from clip

on window lift panel.

3. Remove 2 studs securing latch to window lift

panel.

4. Disconnect outer cable from abutment bracket.

5. Release remote cable from latch.

6. Release sill button link rod from latch. Remove

latch.

Refit

7. Lubricate new latch.

8. Fit latch to sill button link rod.

9. Fit remote control cable to latch.

10. Fit latch to window lift panel, secure with 2

retaining studs.

11. Refit window lift motor/control unit assembly.

See ELECTRICAL, Repair.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

FIXED QUARTER LIGHT - REAR DOOR

Service repair no - 76.31.31

Remove

1. Remove outer waist seal.

See this section.

2. Remove door trim casing.

See this section.

3. From inside release seal from frame. Remove

seal and glass assembly outwards.

4. Remove seal from glass.

Refit

5. Clean glass, seal and frame.

6. Fit seal to glass. Fit assembly to door frame. If

necessary use a draw string to locate rubber.

NOTE: The opening light seal fits over the

fixed glass seal.

7. Fit door trim casing.

See this section.

8. Fit outer waist seal.

See this section.

REMOTE CONTROL - REAR DOOR

Service repair no - 76.37.32

Remove

1. Remove rear door trim casing.

See this

section.

2. Release plastic sheet to clear remote.

3. Remove foam pad from under window lift switch

multiplug.

4. Disconnect switch multiplug.

5. Release inner cable from remote lever.

6. Remove 2 screws securing remote to window lift

control panel.

7. Release remote outer cable from remote

housing.

8. Remove remote control.

Refit

9. Reverse removal procedure.

CHASSIS AND BODY

REPAIR

GLASS CHANNEL - REAR DOOR

Service repair no - 76.31.17

Remove

1. Remove window lift motor/control panel

assembly.

See ELECTRICAL, Repair.

2. Remove 2 bolts securing channel to door and

remove channel.

Refit

3. Fit channel to door, secure with 2 bolts.

4. Refit window lift motor/control panel assembly.

See ELECTRICAL, Repair.

SEAL - REAR DOOR

Service repair no - 76.40.02

Remove

1. Open rear door.

2. Remove rear door carpet retainer.

3. Remove rear door aperture seal.

Refit

4. Fit rear door aperture seal.

5. Refit rear door carpet retainer.

6. Close rear door.

TRIM CASING - REAR DOOR

Service repair no - 76.34.04

Remove

1. Remove remote handle escutcheon.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

2. Remove 2 screws securing trim casing.

3. Release 11 door trim casing retaining studs.

4. Disconnect rear door speaker connector.

Remove door trim casing.

Disassemble

5. Remove 11 trim casing retaining studs.

6. Remove 4 screws, remove upper speaker grille.

7. Remove 4 screws, remove lower speaker grille.

8. Remove 3 screws, remove arm rest.

9. Remove screw, remove retaining clamp and sill

button escutcheon.

CHASSIS AND BODY

REPAIR

10. Remove trim from door casing.

Assemble

11. Fit trim to door casing.

12. Fit sill button escutcheon and position retaining

clamp.

13. Tighten screw securing retaining clamp.

14. Fit arm rest to trim casing, secure with 3 screws.

15. Fit upper speaker grille to trim casing, secure

with 4 screws.

16. Fit lower speaker grille to trim casing, secure

with 4 screws.

17. Fit 11 trim casing retaining studs.

Refit

18. Fit and align door trim casing.

19. Secure 11 trim casing retaining studs.

20. Tighten 2 screws securing trim casing.

21. Fit remote handle escutcheon, tighten securing

screw.

OUTER WAIST SEAL - REAR DOOR

Service repair no - 76.31.54

Remove

1. Remove screw securing seal finisher to forward

edge of door.

2. Release seal finisher from clip at rear edge of

door.

3. Remove seal and finisher assembly.

4. Remove screw and securing clip.

Refit

5. Fit clip to door, secure with screw.

6. Fit seal and finisher assembly to door. Align at

forward edge, secure with screw.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

RUBBING STRIPS & DOOR FINISHERS

Remove

CAUTION: When removing exterior trim,

NEVER lever directly against body panels.

Use an approved trim fork. Protect body

panel with suitable material, such as fabric

covered hardboard.

Rubbing Strip - Front Fender

1. Remove relevant wheel arch liner.

See this

section.

2. Remove nut securing forward edge of rubbing

strip.

3. Remove rubbing strip from single clip.

Rubbing Strip - Rear Quarter Panel

4. Release 5 clips securing rubbing strip. Remove

strip.

NOTE: Rearmost clip is unique.

Rubbing Strips - Front & Rear Doors

5. Remove nut securing rear of rubbing strip.

6. Front Door Rubbing Strip: Release 5 clips

securing rubbing strip.

7. Rear Door Rubbing Strip: Release 3 clips

securing rubbing strip.

8. Remove rubbing strips.

Lower Door Finishers

9. Remove screw securing rear of fininsher.

10. Front Door Finisher: Release 5 clips securing

rubbing strip.

11. Rear Door Finisher: Release 3 clips securing

rubbing strip.

12. Remove finishers.

Refit

13. Reverse removal procedure.

GLOVE BOX AND LID

Service repair no - 76.52.03 - Glove Box

Service repair no - 76.52.02 - Glove Box Lid

Service repair no - 76.52.13 - Glove Box Lid - Align

Remove

1. Remove centre screw from 2 scrivet fasteners.

Release closing panel for access to glove box

hinge fixings. Collect outer parts of fasteners

from closing panel.

2. Remove 2 bolts securing glove box hinges to

fascia frame.

3. Open glove box lid, remove 5 screws securing

glove box. Release glove box from fascia.

4. Disconnect glove box lamp multiplug.

CHASSIS AND BODY

REPAIR

5. Disconnect cable latch, remove glove box

assembly.

Glove Box Lid

6. Remove split pin, disengage gas strut from lid.

7. Remove 2 bolts and square nuts, remove lid

from glove box.

Refit Glove Box Lid

8. Position lid to glove box and secure with bolts

and square nuts.

9. Engage gas strut, secure with split pin.

Refit Glove Box Assembly

10. Position glove box assembly, connect lamp

multiplug. Secure cable latch.

11. Open glove box lid, align assembly to fascia.

Secure with screws.

12. Fit bolts securing hinges to fascia frame, do no

tighten.

13. Check alignment and latching of glove box lid,

adjusting hinges as necessary using central

adjusting screws.

14. Tighten screws, hinges to fascia.

15. Close glove box lid.

16. Position closing panel. Secure with scrivet

fasteners.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

GLOVE BOX RELEASE CABLE

Service repair no - 76.52.14

NOTE: Release cables are supplied preset

and do not normally require adjustment.

Remove

1. Open glove box. Remove 5 screws securing

glove box liner to fascia.

2. Lower glove box liner. Release 2 clips to

disengage cable latch from location.

3. Remove finisher from lock.

4. Remove 2 screws securing lock and withdraw

cable assembly from fascia.

5. Pry cover from lock button.

6. Insert key into lock, turn key through 45 degrees,

remove barrel.

Refit

7. Insert barrel, turn to engage in button.

8. Remove key, fit cover to lock button.

9. Route release cable assembly into fascia.

Engage cable latch to glove box.

10. Align glove box liner to fascia, tighten screws.

11. Close glove box lid.

12. Position glove box lock to fascia, check

operation of latch.

13. If adjustment is necessary, release lock from

fascia, loosen cable lock nut, adjust outer cable

length. Tighten cable lock nut.

14. Reposition lock to fascia. Recheck operation of

latch before securing lock with screws.

15. Fit finisher to lock.

CHASSIS AND BODY

REPAIR

GRAB HANDLE

Service repair no - 76.58.30

Remove

1. Pull down grab handle.

2. Remove 2 grab handle retaining screw access

covers.

3. Remove 2 screws, remove grab handle.

Refit

4. Position grab handle, fit 2 retaining screws.

5. Fit 2 retaining screw access covers.

6. Release grab handle.

FRONT GRILLE

Service repair no - 76.55.03

Remove

1. Remove 6 screws securing grille.

2. Remove front grille.

Refit

3. Reverse removal procedure.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

EXTERIOR MIRROR

Service repair no - 76.10.52

Remove

1. Release cheater panel, disconnect 2 tweeter

speaker connectors. Remove cheater panel.

2. Disconnect mirror multiplug.

3. Remove 3 screws, remove mirror.

Refit

4. Fit mirror, tighten 3 retaining screws.

5. Connect mirror multiplug.

6. Position cheater panel, connect 2 tweeter

speaker connectors, secure panel to door.

INTERIOR MIRROR

Service repair no - 76.10.51

Remove

1. Remove cover.

2. If fitted, diconnect multiplug.

3. Remove mirror from windscreen location by

pulling sharply downwards.

Refit

4. Reverse removal procedure.

CHASSIS AND BODY

REPAIR

PARCEL TRAY SUPPORT

Service repair no - 76.67.11

Remove

1. Release 2 squab catches and fold rear seats

forward.

2. Remove parcel tray.

3. Remove 3 studs securing parcel tray support.

Remove support.

Refit

4. Reverse removal procedure.

PARCEL TRAY SUPPORT TRIM

Service repair no - 76.67.12 - Right Hand

Service repair no - 76.67.21 - Left Hand

Remove

1. Remove parcel tray support.

See this section.

2. Remove ’D’ post lower trim.

3. Release tailgate aperture seal from support trim

flange.

4. Remove 3 trim studs.

LH Trim Only

5. Remove CD autochanger.

See ELECTRICAL,

Repair.

6. Remove 2 nuts and 2 bolts securing sub-woofer

assembly.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

7. Disconnect multiplug from sub-woofer.

Both Trim Panels

8. Release 2 sprag clips securing support trim to

body.

9. Remove support trim panel.

10. LH Trim Only: Separate sub-woofer from trim

panel.

Refit

11. Reverse removal procedure.

A,B,D and E POST TRIMS

Remove

1. Remove aperture seal from appropriate area.

2. Remove retaining screws (’A’ post lower trims)

3. Remove seat belt top mounting (’B’ and ’D’ post

upper trims)

4. Release retaining clips, remove finisher.

Refit

5. Position finisher, secure with retaining clips and

screws.

6. Fit seat belt top mounting. Tighten to

25 Nm.

(18lbf. ft)

7. Secure aperture seal.

NOTE: Illustration 76M 7128 shows the

fixing method for the A, B, D and E post

trim finishers.

1. A post upper

2. A post lower left hand

3. A post lower right hand

4. B post upper

5. B post lower

6. D post upper

7. D post lower

8. E post

CHASSIS AND BODY

REPAIR

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

’E’ POST - EXTERIOR TRIM

Service repair no - 76.43.

Remove

1. Open upper tailgate.

2. Remove 3 screws securing trim to ’E’ post.

3. Remove trim.

Refit

4. Position trim to ’E’ post, engage slot beneath

special washer on tailgate strut ball joint and

engage channel to rear edge of quarter glass.

5. Secure trim with screws.

6. Close tailgate.

SEAT BELT - FRONT

Service repair no - 76.73.13

Remove

1. Remove lower ’B’ post finisher.

2. Remove cover and nut securing seat belt to

upper anchorage point.

3. Release seat belt guide from ’B’ post.

4. Move seat fully forwards.

5. Remove bolt cover. Release seat belt from lower

anchorage point on seat.

CHASSIS AND BODY

REPAIR

6. Remove bolt securing belt reel to ’B’ post,

remove belt reel.

7. Move seat fully rearwards.

8. Remove cover from seat belt stalk fixing.

Remove bolt. Collect stalk.

Refit

9. Position seat belt stalk. Secure with retaining

bolt. Tighten to

35 Nm. (26 lbf.ft).

Fit bolt

cover.

10. Fit seat belt reel to ’B’ post. Secure with retaining

bolt. Tighten to

35 Nm. (26 lbf.ft)

11. Move seat fully forwards.

12. Secure seat belt to lower anchorage point. Fit

bolt cover.

WARNING: Ensure that belt is correctly

located before fitting bolt cover.

13. Align belt to upper anchorage point. Secure with

nut. Tighten to

25 Nm. (18 lbf.ft).

Fit cover.

14. Secure seat belt guide to ’B’ post.

15. Refit lower ’B’ post finisher.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

FRONT SEAT BELT ADJUSTABLE MOUNTING

Service repair no - 76.73.26

Remove

1. Remove ’B’ post trim upper.

2. Remove 2 screws securing adjustable mounting.

Remove mounting.

Refit

3. Position adjustable mounting. Secure with

screws. Tighten to

25 Nm. (18 lbf.ft)

4. Fit ’B’ post trim upper.

SEAT BELT ADJUSTABLE MOUNTING - ’D’ POST

Service repair no - 76.73.36

Remove

1. Remove ’D’ post trim - upper.

2. Remove 2 screws securing adjustable mounting.

Remove mounting.

Refit

3. Position adjustable mounting. Secure with

screws. Tighten to

25 Nm. (18 lbf.ft)

4. Refit ’D’ post trim - upper.

CHASSIS AND BODY

REPAIR

REAR SEAT BELT - CENTRE

Service repair no - 76.73.20

Remove

1. Remove right hand rear seat.

See SEATS,

Repair.

2. Remove 3 screws securing squab hinge cover.

Remove cover.

3. Remove 2 bolts securing squab to cushion

assembly.

4. Remove squab from cushion assembly.

5. Remove bolt and wave washer securing stalk to

squab hinge. Remove stalk. Collect plain

washer.

6. Release beaded edge of cushion cover from

seat pan flange. Remove cushion cover/foam

assembly.

CAUTION: Take care when releasing

cover/foam from belt anchorage finisher.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

7. Remove 3 screws securing anchorage cover to

seat pan. Remove cover in 2 pieces.

8. Remove bolt securing seat belt to seat pan.

Remove belt, collect spacer.

Refit

9. Fit seat belt to seat pan. Secure with bolt and

spacer. Tighten to

35 Nm. (26 lbf.ft)

10. Fit seat belt anchorage cover. Secure with

screws.

11. Fit cushion assembly to seat pan. Secure

beaded edge of cover to seat pan flange.

12. Fit stalk to squab hinge. Secure with bolt.

Tighten to

35 Nm. (26 lbf.ft)

13. Position seat squab to cushion assembly.

Secure with bolts. Tighten to

45 Nm. (33 lbf.ft)

14. Refit squab hinge cover. Secure with screws.

15. Refit rear seat assembly.

See SEATS, Repair.

CHASSIS AND BODY

REPAIR

REAR SEAT BELT - LEFT HAND

Service repair no - 76.73.23

Remove

1. Remove parcel shelf support trim.

See this

section.

2. Remove ’D’ post lower trim.

See this section.

3. Remove cover and nut securing seat belt to

upper anchorage point.

4. Remove bolt securing seat belt reel.

5. Remove seat belt reel.

6. Remove left hand rear seat.

See SEATS,

Repair.

7. Remove 3 screws securing squab hinge cover.

Remove cover.

8. Remove 2 bolts securing squab to cushion

assembly.

9. Remove squab from cushion assembly.

10. Remove bolt and wave washer securing stalk to

squab hinge.

11. Remove stalk. Collect plain washer.

Refit

12. Fit stalk to squab hinge. Secure with bolt.

Tighten to

35 Nm. (26 lbf.ft)

13. Position seat squab to cushion assembly.

Secure with bolts. Tighten to

45 Nm. (33 lbf.ft)

14. Refit squab hinge cover. Secure with screws.

15. Refit rear seat assembly.

See SEATS, Repair.

16. Position belt to upper anchorage point. Secure

with nut. Tighten to

25 Nm. (18 lbf.ft).

Fit

cover.

17. Position seat belt reel. Secure with bolt. Tighten

35 Nm. (26 lbf.ft)

18. Fit ’D’ post lower trim.

See this section.

19. Fit parcel shelf support trim.

See this section.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

REAR SEAT BELT - RIGHT HAND

Service repair no - 76.73.24

Remove

1. Remove parcel shelf support trim.

See this

section.

2. Remove ’D’ post lower trim.

3. Remove cover and nut securing seat belt to

upper anchorage point.

4. Remove bolt securing seat belt reel.

5. Remove seat belt reel.

6. Remove right hand rear seat.

See SEATS,

Repair.

7. Remove 3 screws securing squab hinge cover.

Remove cover.

8. Remove 2 bolts securing squab to cushion

assembly. Remove squab.

9. Release beaded edge of cushion cover from

seat pan flange. Remove cushion cover/foam

assembly.

CHASSIS AND BODY

REPAIR

CAUTION: Take care when releasing

cover/foam from belt anchorage finisher.

10. Remove 3 screws securing anchorage cover to

seat pan. Remove cover in 2 pieces.

11. Remove bolt securing stalk to seat pan. Remove

stalk. Collect 2 spacers and wave washer.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

Refit

12. Fit stalk to seat pan. Secure with bolt, spacers

and wave washer. Tighten to

35 Nm. (26 lbf.ft)

13. Fit seat belt anchorage cover. Secure with

screws.

14. Fit cushion assembly to seat pan. Secure

beaded edge of cover to seat pan flange.

15. Fit stalk to squab hinge. Secure with bolt.

Tighten to

35 Nm. (26 lbf.ft)

16. Position seat squab to cushion assembly.

Secure with bolts. Tighten to

45 Nm. (33 lbf.ft)

17. Refit squab hinge cover. Secure with screws.

18. Refit rear seat assembly.

See SEATS, Repair.

19. Position belt to upper anchorage point. Secure

with nut. Tighten to

35 Nm. (26 lbf.ft).

Fit

cover.

20. Position seat belt reel. Secure with bolt. Tighten

35 Nm. (26 lbf.ft)

21. Fit ’D’ post lower trim.

22. Fit parcel shelf support trim.

See this section.

CHASSIS AND BODY

REPAIR

SLIDING ROOF - ELECTRIC

Service repair no - 76.82.44

Remove

1. Remove headlining.

See this section.

2. Disconnect motor multiplug.

3. Disconnect sliding roof drain tubes.

4. Remove 8 bolts securing sliding roof.

5. With assistance, remove 2 remaining bolts.

Remove sliding roof.

6. Remove seal from sliding roof.

Refit

7. Ensure mating faces are clean.

8. Fit new seal to sliding roof.

9. With assistance, position sliding roof. Fit 2 bolts.

10. Fit remaining bolts.

11. Connect drain tubes. Secure with clips.

12. Connect motor multiplug.

13. Refit headlining.

See this section.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

HEADLINING - SLIDING ROOF

Service repair no - 76.64.15

Remove

1. Remove upper trims from ’A’,’B’,’D’ & ’E’ posts.

See this section.

2. Remove both sun visors.

See this section.

3. Remove grab handles.

See this section.

4. Remove parcel tray support trim.

See this

section.

5. Remove interior lamps.

See ELECTRICAL,

Repair.

6. Remove front courtesy lamp.

See

ELECTRICAL, Repair.

7. Remove ultrasonic sensor.

See ELECTRICAL,

Repair.

8. Fold down rear seat squabs. Recline front seat

squabs.

9. Release aperture sealing rubbers at tops of

doors and tailgate.

10. Release sun visor clip retaining screw cover

plugs.

11. Remove sun visor retaining clip screws. Remove

clips.

12. Remove sun roof aperture finisher.

13. Remove 2 headlining grab handle blanks.

14. Remove 2 studs securing rear of headlining.

15. With assistance remove headlining.

Refit

16. Reverse removal procedure.

CHASSIS AND BODY

REPAIR

SUNROOF DRAIN TUBE - FRONT

Service repair no - 76.82.21

Remove

1. Remove headlining.

See this section.

2. Remove wheelarch liner.

See this section.

3. Release drain tube from sunroof.

4. Release drain tube grommet from body behind

wheel arch liner.

5. Tie draw string to one end of drain tube and pull

tube from ’A’ post.

Refit

6. Tie draw string to new drain tube and pull

through ’A’ post.

7. Fit grommet to drain tube, secure to body.

8. Secure drain tube to sunroof.

9. Fit headlining.

See this section.

10. Refit wheel arch liner.

See this section.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

SUNROOF DRAIN TUBE - REAR

Service repair no - 76.82.22

Remove

1. Remove headlining.

See this section.

NOTE: Ensure that parcel shelf support

panel is removed from side of drain tube

to be removed.

2. Release clip from drain tube.

3. Disconnect drain tube from sunroof.

4. Remove drain tube from wheel arch grommet.

Refit

5. Fit drain tube to sunroof, secure with clip.

6. Fit drain tube through wheel arch grommet.

7. Refit headlining.

See this section.

CHASSIS AND BODY

REPAIR

SUN VISOR

Service repair no - 76.10.47

Remove

1. Release visor from clip.

2. Remove 3 visor retaining screws.

3. Disconnect visor lamp multiplug.

4. Remove visor.

5. Remove clip if required. Carefully lever plastic

tag down.

6. Remove screw, remove clip.

Refit

7. Reverse removal procedure.

SILL FINISHER

Service repair no - 76.43.84

Remove

1. Remove 3 screws securing front tread plate.

2. Remove 2 screws securing rear tread plate.

3. Remove trim stud securing rear of sill finisher.

4. Release 8 clips securing finisher to sill.

5. Remove sill finisher.

Refit

6. Renew clips as necessary.

7. Reverse removal procedure.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

TAILGATE - UPPER

Service repair no - 76.28.29

Remove

1. Remove both ’E’ post finishers.

2. Remove 2 trim fixing studs. Release headlining

from ’E’ posts.

3. Release 4 turn buckles securing access panel to

LH side load space trim. Remove panel.

4. Locate rear screen washer non-return valve.

Disconnect tailgate feed tube from valve.

5. Attach draw string to tube to aid re-assembly.

6. Release tailgate harness protective sleeve from

roof panel.

7. Disconnect 3 tailgate harness multiplugs from

body harness. Pull plugs out through hole in roof

panel.

8. Pull screen washer tube out through hole in roof

panel. Disconnect draw string.

9. Mark outline of hinge on tailgate to aid

re-assembly.

10. Apply protective tape to roof panel before

releasing tailgate.

11. With assistance, disconnect gas struts from

tailgate.

12. With assistance, remove 4 bolts securing hinges

to tailgate. Remove tailgate.

CHASSIS AND BODY

REPAIR

Refit

13. With assistance, position tailgate to hinges. Align

marks. Secure with bolts. Tighten to

25 Nm. (18

lbf.ft)

14. With assistance, connect gas struts to tailgate.

15. Remove protective tape from roof panel.

16. Attach draw string to washer tube. Pull tube

along roof into position at ’E’ post. Remove draw

string.

17. Connect tube to non-return valve.

18. Feed 3 tailgate harness multiplugs through roof

panel. Connect to body harness.

19. Secure tailgate harness protective sleeve to roof

panel.

20. Reposition headlining at ’E’ posts. Secure with

studs.

21. Fit load space access panel. Secure with turn

buckles.

22. Fit both ’E’ post finishers.

Adjust

23. Check alignment of lower tailgate.

See this

section.

24. Align tailgate to aperture by adjusting position of

hinges on tailgate or body.

25. Align tailgate to adjacent body panels by

adjusting position of hinges on body.

NOTE: To prevent wind noise, ensure top

edge of tailgate does not stand proud of

roof panel.

TAILGATE - LOWER

Service repair no - 76.28.30

Remove

1. Remove parcel tray support trim from RH side of

luggage area.

See this section.

2. Disconnect tailgate harness multiplug from body

harness. Release grommet from lower of ’E’

post. Pull harness from body.

3. Fit protection under tailgate.

4. Mark outline of hinges to body to aid

reassembly.

5. Remove bolt securing each check strap to body.

Collect spacer and fibre sealing washer.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

6. With assistance, remove bolts securing tailgate

hinges to body. Remove tailgate complete with

hinges.

Refit

7. With assistance, position tailgate to body.

Secure with bolts. Tighten to

25 Nm. (18 lbf.ft)

8. Position support stays with spacer and sealing

washer next to body. Tighten to

22 Nm. (16

lbf.ft)

9. Remove protection.

10. Feed tailgate harness into ’E’ post. Connect

multiplug to body harness.

11. Fit harness grommet to ’E’ post.

12. Fit parcel tray support trim.

See this section.

Adjust

13. Align tailgate to aperture by adjusting position of

hinges on tailgate or body.

14. Align tailgate to adjacent body panels by

adjusting position of hinge to tailgate.

15. When tailgate alignment is correct, adjust height

and inboard/outboard position of each striker.

Tighten striker bolts. Check for correct latching.

16. Slacken bolts, re-adjust striker positions as

necessary. Tighten to

8 Nm. (6 lbf.ft)

TAILGATE STRIKER

Service repair no - 76.37.26

Remove

1. Remove 2 bolts securing striker. Remove striker.

Refit

2. Position striker. Secure with bolts

3. Close tailgate. Check alignment.

4. If necessary, open tailgate, slacken bolts, realign

striker. Re-tighten bolts.

CHASSIS AND BODY

REPAIR

TAILGATE LATCH

Service repair no - 76.37.17

Remove

1. Release studs securing tailgate board. Remove

board.

2. Release clips securing operating rods to tailgate

centre latch. Release rods.

3. Disconnect latch multiplug.

4. Remove 2 bolts securing latch to tailgate.

Remove latch.

Refit

5. Reverse removal procedure.

TAILGATE LATCH - OUTER

Service repair no - 76.37.73

Remove

1. Release studs securing tailgate board. Remove

board.

2. Release clip securing outer latch rod. Disconnect

rod from centre latch.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

3. Remove 2 bolts securing outer latch to tailgate.

Remove latch and rod.

4. Rotate release rod 90˚ to remove from outer

latch.

Refit

5. Reverse removal procedure.

UPPER TAILGATE - INTERIOR TRIM

Service repair no - 76.34.13

Remove

Lower trim assembly

1. Release load space lamp from trim panel,

disconnect 2 Lucar terminals and remove lamp.

2. Remove 6 screws securing trim panel to side

trims and tailgate.

3. Release 4 studs securing trim panel to tailgate.

4. Disconnect high level stop lamp multiplug, if

fitted.

5. Remove lower trim assembly.

Upper trim

6. Remove 6 screws securing trim panel to tailgate.

CHASSIS AND BODY

REPAIR

7. Remove trim panel and collect 2 foam pads.

Side trims

8. Release 3 studs securing each side trim.

9. Remove 2 side trims.

Refit

10. Reverse removal procedure.

TAILGATE STRUT

Service repair no - 76.40.33

Remove

1. Secure tailgate in open position using suitable

support.

2. Release clips securing strut to ball joints.

Remove strut.

Refit

3. Reverse removal procedure.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

WHEEL ARCH LINER - FRONT

Service repair no - 76.10.48

Remove

1. Raise the vehicle.

WARNING: Support on safety stands.

2. Remove relevant road wheel.

3. Remove 3 screws securing mud flap. Remove

mud flap.

4. Remove 8 studs securing wheel arch liner.

Refit

5. Position liner and secure with trim studs.

6. Fit mud flap and secure with screws.

7. Refit road wheel. Secure with nuts. Tighten to

108 Nm. (80 lbf.ft)

8. Remove safety stands. Lower vehicle.

WHEEL ARCH LINER - REAR

Service repair no - 76.10.49

Remove

1. Raise the vehicle.

WARNING: Support on safety stands.

2. Remove relevant road wheel.

3. Remove screws from wheel arch liner fixings.

Remove fixings.

4. Remove liner.

Refit

5. Position liner. Fit liner fixings. Secure with

screws.

6. Refit road wheel. Secure with nuts. Tighten to

108 Nm. (80 lbf.ft)

7. Remove safety stands. Lower vehicle.

CHASSIS AND BODY

REPAIR

WINDSCREEN

Service repair no - 76.81.01

NOTE: The following equipment is

required:

masking tape;

sharp knife;

reciprocating blade, powered cutting knife*, or

cutting wire and handles;

suction lifters;

windscreen repair kit;

sealer applicator gun.

* A reciprocating blade cutting tool, such as ’FEIN

Special Cutter’, is recommended for this operation. A

flat blade, with an effective length of at least 25mm

and a ’U’ shaped blade of at least 30mm is required.

CAUTION: Extreme care is necessary to

ensure that paintwork and trim does not

become damaged during the removal

process.

Particular care should be taken when using

cutting wire and handles to avoid damage to seal

along leading edge of fascia.

WARNING: Wear protective gloves when

handling glass, solvents and primers.

Remove

1. Remove interior mirror.

See this section.

2. Remove plenum panels.

See HEATING AND

VENTILATION, Repair.

3. Insert a thin plastic strip, such as a credit card,

between windcreen upper finisher and roof

panel.

4. Disengage 8 clips securing upper finisher by

sliding clips towards left hand side of vehicle.

5. Remove upper screen finisher.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

6. If fitted, disconnect heating element multiplugs.

Disconnect heating element earth wire. Tape

heater connections onto windscreen to prevent

fouling during removal procedure.

7. Mask around windscreen aperture to protect

paintwork.

8. Fit protective cover over fascia and bonnet.

Removal Using Reciprocating Blade Tool

9. Cut through P.U. adhesive along sides of screen

using flat blade.

10. Using a ’U’ shaped blade, cut through adhesive

bead along upper and lower edges of screen.

CAUTION: Access to adhesive around

lower screen supports is restricted.

Manoeuvre blade to cut as much sealant

from around screen supports as possible.

11. Attach suction lifters to glass. With assistance,

cut through remaining sealant around screen

supports using a sharp knife.

12. With assistance, remove windscreen glass.

Removal Using Cutting Wire and Handles.

13. Remove both ’A’ post finishers.

See this

section.

14. Remove both sun visors.

See this section.

15. Remove map/courtesy lamp assembly.

See

ELECTRICAL, Repair.

CHASSIS AND BODY

REPAIR

16. Mask along leading edge of headlining.

17. Using a sharp knife, cut through P.U. sealer at

side of screen, towards lower corner.

18. Insert cutting wire through knife cut and fit

handles, as shown, with approximately 200 mm

(8 in) of wire between handles.

19. With assistance, wedge tube of handle ’A’

between glass and body, ahead of the cutting

position, and carefully cut the sealer using a

continuous pull on handle ’B’ from the outside.

Cut side and top edges first. Attach suction lifters

and restrain glass as last of sealant is cut.

NOTE: When cutting along lower edge,

manoeuvre wire between glass edge and

screen supports to reduce strain on wire.

20. Attach suction lifters to glass. With assistance,

remove windscreen.

Refit

21. carefully cut old sealer from body flange to

obtain a smooth surface, approximately 2 mm

(1/16 in) thick.

CAUTION: Do not cut down to painted

surface.

22. Inspect supports, renew if damaged.

23. Position screen on felt covered surface.

24. If original screen is to be refitted, cut old sealer

from glass to obtain a smooth surface,

approximately 2 mm (1/16 in) thick.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

CAUTION: Do not cut down to surface of

glass.

25. Position and centralise new windscreen to body.

Apply tape reference marks to aid final fitment.

Remove screen and position to work surface.

26. Apply cleaning solvent to sealing surface of

glass and body flange.

CAUTION: Do not touch cleaned or primed

areas with fingers.

27. Position 5 screen spacer blocks on inside edge

of glass, over cut-out marks in obscuration band.

28. If necessary, peel off backing strip and stick

foam glazing dam along inside surface of glass,

approximately 13 mm (1/2 in) from top edge.

29. Shake primer tins for at least 30 seconds. Apply

body primer to sealing surface of body flange

using supplied applicator.

30. Apply glass primer to sealing surface of glass.

CAUTION: Use a separate applicator for

each primer.

31. Remove lid from sealer cartridge, remove

crystals, pierce membrane and fit pre-cut nozzle.

Fit cartridge to applicator gun.

NOTE: The profile of the nozzle must be

modified slightly to produce the required

bead section.

CHASSIS AND BODY

REPAIR

32. Apply a continuous bead of sealer to windscreen

as shown.

33. Fit suction lifters to glass.

34. With assistance, position glass centrally, using

previously made tape markings and lower onto

supports. Seat glass to spacer blocks.

CAUTION: Do not apply heavy pressure to

the sides of the screen. Lightly press

screen from centre outwards until edges

are to required gap. Pushing screen edges into

position can bend screen and lead to cracking in

service.

35. Remove protection from fascia and bonnet.

36. Remove masking tape.

37. If fitted, connect heating element multiplugs and

earth wire.

38. Remove clips from upper screen finisher.

39. Fit clips to body studs. Position upper screen

finisher and engage to clips.

40. Fit plenum panels.

See HEATING AND

VENTILATION, Repair.

41. Fit interior mirror.

See this section.

If Cutting Wire and Handles Used

42. Remove masking from leading edge of

headlining.

43. Fit map/courtesy lamp assembly.

See

ELECTRICAL, Repair.

44. Fit sun visors.

See this section.

45. Fit ’A’ post finishers.

See this section.

CAUTION: A curing time of 6 hours is

recommended. During this time, leave the

windows open and DO NOT slam the

doors.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

WINDSCREEN LOWER FINISHER

Service repair no - 76.43.41

Remove

1. Remove both windscreen side finishers.

See

this section.

2. Remove both windscreen wiper arms.

See

WIPERS AND WASHERS, Repair.

3. Release 10 clips securing windscreen lower

finisher.

4. Remove windscreen lower finisher.

Refit

5. Reverse removal procedure.

WINDSCREEN SIDE FINISHER

Service repair no - 76.43.39

Remove

1. Lift side finisher seal to reveal fixings.

2. Remove 4 screws securing side finisher.

3. Remove side finisher.

Refit

4. Position side finisher. Secure side with screws.

CHASSIS AND BODY

REPAIR

BACKLIGHT GLASS

Service repair no - 76.81.10

NOTE: The following equipment is

required:

masking tape.

Sharp knife.

Cutting wire and handles, or a reciprocating

blade, powered cutting knife*.

Suction lifters.

Windscreen repair kit.

Sealer applicator gun.

*A reciprocating blade cutting tool, such as ’FEIN

Special Cutter’ is recommended for this operation. A

flat blade, with an effective length of at least 25mm

and a ’U’ shaped blade of at least 30mm are required.

WARNING: Wear protective gloves when

handling glass, solvents and primers.

Remove

1. Remove interior trim from tailgate,

See this

section.

2. Release backlight lower finisher from 7 clips.

3. Remove backlight lower finisher.

4. Remove backlight side finishers.

NOTE: Side finishers are secured to

backlight with P.U. sealer. New backlight

glasses are supplied with side finishers

fitted. Side finishers are available separatley if

original glass is to be refitted.

5. Remove rubber finisher from upper edge of

backlight glass.

6. Protect tailgate panel with masking tape.

7. Disconnect two Lucar terminals from screen

heater element.

Removal Using Reciprocating Blade Tool

8. Cut through P.U. adhesive along sides of screen

using flat blade.

9. Using a ’U’ shaped blade, cut through adhesive

bead along upper and lower edges of glass.

CAUTION: Access around lower clips is

restricted. Manoeuvre blade to cut through

as much adhesive as possible.

10. Attach suction lifters to glass. With assistance,

cut through remaining sealant around lower

clips.

11. With assistance, remove backlight glass.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

Removal Using Cutting Wire Handles

12. Using a sharp knife, cut through P.U. sealer at

side of backlight.

13. Insert cutting wire through knife cut and fit

handles, as shown, with approximatley 200mm

of wire between handles.

14. With assistance, wedge tube of handle ’A’

between glass and body, ahead of the cutting

position, and carefully cut the sealer using a

continuous pull on handle ’B’ from the outside.

Cut side and top edges first. Attach suction lifters

and restrain glass as last of sealant is cut.

NOTE: When cutting along lower edge,

manoeuvre wire between glass edge and

finisher clips to reduce strain on wire.

15. With assistance, remove backlight glass.

Refit

16. Carefully cut old sealer from body flange to

obtain a smooth surface, approximately 2mm

thick.

CAUTION: Do not cut down to painted

surface.

17. Renew broken finisher clips as necessary.

Position finisher clips centrally on tailgate studs.

NOTE: Clips control height and seating of

lower glass edge.

18. Position and centralize new backlight to tailgate.

Apply tape reference mark to aid final fitment.

19. Position new backlight on felt covered surface.

20. Fit and centralize rubber finisher to top of glass.

NOTE: Finisher controls seating depth of

glass top edge.

21. Apply cleaning solvent to sealing surface of

glass and body flange.

CAUTION: Do not touch cleaned or primed

areas with fingers.

22. Shake primer tins for at least 30 seconds. Apply

body primer to sealing surface of body flange

using supplied applicator.

23. Apply glass primer to sealing surface of glass.

CAUTION: Use a separate applicator for

each primer.

24. Remove lid from sealer cartridge, remove

crystals, pierce membrane and fit pre-cut nozzle.

Fit cartridge to applicator gun.

NOTE: The profile of the nozzle must be

modified slightly to produce the required

bead section.

CHASSIS AND BODY

REPAIR

25. Apply a continuous bead of sealer to backlight

as shown.

26. Original glass:Apply 3mm bead of sealer to

channels of side finishers and fit to backlight.

27. Fit suction lifters to glass.

28. With assistance, fit glass and centralize to

previously made tape markings. Set glass to

correct depth.

29. Connect screen heater.

30. Remove reference and protective tapes.

31. Position lower finisher and secure to clips.

32. Fit interior trim to tailgate,

See this section.

CAUTION: A curing time of 6 hours is

recommended. During this time, leave the

windows open and DO NOT slam the

doors.

REAR QUARTER LIGHT

Service repair no - 76.81.20

NOTE: The following equipment is

required:

Masking tape.

Sharp knife.

Cutting wire and handles, or a reciprocatig

blade, powered cutting knife*.

Suction Lifters.

Windscreen repair kit.

Sealer applicator gun.

*A reciprocating blade cutting tool, such as ’FEIN

Special Cutter’ is recommended for this operation. A

flat blade, with an effective length of at least 25mm

and a ’U’ shaped blade of at least 30mm is required.

NOTE: New rear quarter glass is supplied

with exterior trim fitted.

WARNING: Wear protective gloves when

handling glass, solvents and primers.

Remove

1. Remove parcel tray support,

See this section.

2. Remove both ’E’ post trims,

See this section.

3. Remove relevant ’B’ post upper trim,

See this

section.

4. Remove relevant side interior lamp assembly,

See ELECTRICAL, Repair.

5. Remove relevant grab handle,

See this

section.

6. Remove relevant exterior ’E’ post finisher,

See

this section.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

7. Remove 2 trim studs securing headlining to ’E’

posts.

8. Release headlining from tailgate seal. Lower

headlining as necessary during glass removal to

provide access to sealant along top edge of

glass.

9. Disconnect aerial amplifier plugs.

10. R.H. glass only:Disconnect alarm receiver plug.

11. Protect surrounding area of body using masking

tape.

Removal Using Reciprocating Blade Tool

12. Lift flip seal to reveal trim fixings.

13. Remove 2 screws securing exterior trim to ’D’

post.

14. Cut through P.U. adhesive from inside of glass

along lower and side edges.

CHASSIS AND BODY

REPAIR

CAUTION: Manoeuvre knife blade around 3

parcel tray support clips. Ensure aerial

amplifier and alarm reciever plugs do not

become damaged.

15. Attach suction lifters to glass. With assistance,

cut through sealant along top of edge glass.

16. Remove rear quarter glass.

Removal Using Cutting Wire Handles

17. Protect surrounding area of body using masking

tape.

18. Lift flip seal to reveal trim fixings.

19. Remove 2 screws securing exterior trim to ’D’

post.

20. Carefully cut through adhesive bead between

glass and trim using a sharp knife.

NOTE: A reciprocating blade cutting tool,

such as ’FEIN Special Cutter’ will ease the

removal of the trim. Use a cranked blade

with an effective length of not more than 22mm.

21. Remove and discard quarter light trim.

NOTE: Rear quarter lights are supplied

with finisher fitted. Finisher is not

available separately.

22. Using a sharp knife, cut through P.U. sealer at

forward edge of quarter glass.

23. Insert cutting wire through knife cut and fit

handles, as shown, with approximatley 200mm

of wire between handles.

24. With assistance, wedge tube of handles ’A’

between glass and body, ahead of the cutting

position, and carefully cut the sealer using a

continuous pull on handle ’B’ from the outside.

Cut side and top edges first. Attach suction lifters

as last sealant is cut.

NOTE: When cutting along lower edge,

manoeuvre wire between glass edge and

parcel tray support clips to reduce strain

on wire.

CAUTION: Ensure aerial amplifier and

alarm receiver plugs do not become

damaged.

25. Remove rear quarter glass.

CHASSIS AND BODY NEW RANGE ROVER

REPAIR

Refit

26. Carefully cut old sealer from body flange to

obtain a smooth surface, approximatley 2mm

thick.

CAUTION: Do not cut down to painted

surface.

27. Position new quarter glass on felt covered

surface.

28. Apply cleaning solvent to sealing surface of

glass and body flange.

CAUTION: Do not touch cleaned or primed

areas with fingers.

29. Stick 4 self adhesive spacers on the inside edge

of glass at corners.

30. Shake primer tins for at least 30 seconds. Apply

body primer to sealing surface of body flange

using supplied applicator.

31. Apply glass primer to sealing surface of glass.

CAUTION: Use a separate applicator for

each primer.

32. Remove lid from sealer cartridge, remove

crystals, pierce membrane and fit pre-cut nozzle.

Fit cartridge to applicator gun.

NOTE: The profile of the nozzle must be

modified slightly to produce the required

bead section.

33. Apply a continuous bead of sealer to rear quarter

glass as shown.

34. Fit suction lifters to glass.

35. With assistance, fit glass and align to body. Seat

glass to spacer rubbers.

36. Remove protective tape.

37. Secure exterior trim to ’D’ post with screws.

38. Connect aerial amplifier plug.

39. R.H. glass only:Connect alarm receiver plug.

40. Position headlining and engage beneath tailgate

flip seal.

41. Secure headlining to ’E’ posts with trim studs.

42. Fit exterior ’E’ post finisher,

See this section.

43. Fit grab handle,

See this section.

44. Fit side interior lamp assembly,

See

ELECTRICAL, Repair.

45. Fit ’B’ post upper trim,

See this section.

46. Fit ’E’ post trims,

See this section.

47. Fit parcel tray support,

See this section.

CAUTION: A curing time of 6 hours is

recommended. During this time, leave the

windows open and DO NOT slam the

doors.

PANEL REPAIRS

SEALING AND CORROSION PROTECTION

CORROSION PROTECTION

Factory Treatments

The New Range Rover is treated with the following

anti-corrosion materials in production:

• A PVC-based underbody sealer material

which is sprayed onto the underfloor, wheel

arches and undersill areas.

• An application of cavity wax which is

sprayed into enclosed cavities, box

sections and lower inner door panels.

• A final coating of underbody wax to cover

the complete underfloor including

components but excluding brake discs.

• A coat of protective lacquer or wax applied

to the engine bay area.

In addition to the above measures, all steel parts are

zinc-coated both sides, and front wings, door and

tailgate skins are manufactured from aluminium.

The information given on the following pages is

intended as a guide and shows the areas to be

treated with cavity wax, as well as the access holes

used during manufacture. See GENERAL

INFORMATION DATA, Sealing and corrosion

protection section.

Underbody Wax

A coat of underbody wax is applied to the entire

underbody inboard of the sill vertical flanges, and

covers all moving and flexible components EXCEPT

for wheels and tyres, brakes and exhaust. The wax is

applied over paints and underbody sealers.

The underbody wax must be reinstated following all

repairs affecting floor panels.

CAUTION: Old underbody wax must be

completely removed from a zone

extending at least 200mm (7.9in.) beyond

the area where new underbody sealer is to be

applied.

Underbody Sealer

Underfloor areas and outer sill panels are treated with

a Plastisol PVC underbody sealer. This material is not

suitable for re-treatment.

When repairing areas of underbody sealer, strip the

factory-applied material back to a suitable break point,

ensuring that a clean metal surface is exposed and

that the edge of the existing material adheres soundly

to the panel.

Blanking plugs and grommets in the floor pan (except

those used for wax injection) MUST be fitted before

underbody sealer application. Heat-fusible plugs

which have been disturbed should either be refitted

with the aid of a hot air blower or replaced with rubber

grommets.

NOTE: Application of new underbody

sealer must be carried out between primer

and surfacer paint operations. Areas

where seam sealer is used should be re-treated as

necessary before application of underbody sealer.

CAUTION: Ensure that suspension units,

wheels, tyres, power unit, driveshafts,

exhaust and brakes (including all

mounting points) are shielded prior to application

of fresh underbody sealer.

Engine Bay Wax

Reinstate protective engine bay wax disturbed during

repairs using the approved material.

PANEL REPAIRS NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

Stone Chip Resistant Paint/Primer

Re-treat all areas protected with factory-applied

anti-chip primer with suitable approved material in

repair.

Inspections during Maintenance Servicing

It is a requirement of the Land Rover Corrosion

Warranty that the vehicle body is checked for

corrosion by an authorised Land Rover dealer at least

once a year, to ensure that the factory-applied

protection remains effective.

Service Job Sheets include the following operations to

check bodywork for corrosion:

• With the vehicle on a lift, carry out visual

check of underbody sealer for damage.

• With the vehicle lowered, inspect exterior

paintwork for damage and body panels for

corrosion.

NOTE: Wash the vehicle and ensure that it

is free from deposits prior to inspection. It

is part of the owner’s responsibility to

ensure that the vehicle is kept free of

accumulations of mud which could accelerate the

onset of corrosion. The Dealer MUST wash the

vehicle prior to inspection of bodywork if the

customer has offered it in a dirty condition, and

pay special attention to areas where access is

difficult.

NOTE: The checks described above are

intended to be visual only. It is not

intended that the operator should remove

trim panels, finishers, rubbing strips or sound

deadening materials when checking the vehicle

for corrosion and paint damage.

With the vehicle on a lift, and using an inspection or

spot lamp, visually check for the following:

• Corrosion damage and damaged

paintwork, condition of underbody sealer

on front and rear lower panels, sills and

wheel arches.

• Damage to underbody sealer on main floor

and chassis members. Corrosion in areas

adjacent to suspension mountings and fuel

tank fixings.

NOTE: The presence of small blisters in

PVC underbody sealer is acceptable,

providing they do not expose bare metal.

Special attention must be paid to signs of damage

caused to panels or corrosion material by incorrect

jack positioning.

It is essential to follow the correct jacking and lifting

procedures. See GENERAL INFORMATION DATA,

Information section.

With the vehicle lowered, visually check for evidence

of damage and corrosion on all painted areas, in

particular the following:

• Front edge of bonnet.

• Visible flanges in engine compartment and

boot.

• Lower body and door panels.

Where bodywork damage or evidence of corrosion is

found during inspection, rectify this as soon as is

practicable, both to minimise the extent of the damage

and to ensure the long term effectiveness of the

factory-applied corrosion protection treatment. Where

the cost of rectification work is the owner’s

responsibility, the Dealer must advise the owner and

endorse the relevant documentation accordingly.

Where corrosion has become evident and is

emanating from beneath a removable component

(e.g. trim panel, window glass, seat etc.), remove the

component as required to permit effective rectification.

PANEL REPAIRS

SEALING AND CORROSION PROTECTION

Underbody Protection Repairs

When body repairs are carried out, always ensure that

full sealing and corrosion protection treatments are

restored. This applies both to the damaged area, and

also to areas where protection has been indirectly

impaired as a result of accident damage or repair

operations.

Prior to straightening out or panel beating, remove all

corrosion protection material in the damaged area.

This applies in particular to panels coated with wax,

PVC underbody sealer, sound deadening pads etc.

WARNING: DO NOT use oxy-acetylene gas

equipment to remove corrosion prevention

materials. Large amounts of fumes and

gases are liberated by these materials when they

burn.

Equipment for the removal of tough anti-corrosion

sealers offers varying degrees of speed and

effectiveness. The compressed air-operated scraper

(NOT an air chisel) offers a relatively quiet mechanical

method of removal using an extremely rapid

reciprocating action. During use, direct the operating

end of the tool along the work surface.

The most common method is by the use of a hot air

blower with integral scraper.

CAUTION: High temperatures can be

generated with this equipment which may

cause fumes. Always exercise care in its

use.

Another tool, and one of the most efficient methods, is

the rapid-cutting ’hot knife’. This tool uses a wide

blade and is quick and versatile, able to be used

easily in profiled sections where access is otherwise

awkward.

Use the following procedure when repairing

underbody coatings:

1. Remove existing underbody coatings.

2. After panel repair, clean the affected area with a

solvent wipe, and treat bare metal with an etch

phosphate material.

3. Re-prime the affected area. DO NOT under any

circumstances apply underbody sealer

directly to bare metal surfaces.

4. Replace all heat-fusible plugs which have been

disturbed. Use rubber grommets of equivalent

size if plugs are not available, but ensure that

they are embedded in sealer.

5. Mask off all mounting faces from which

mechanical components, hoses and pipe clips,

have been removed. Underbody sealer must be

applied before such components are refitted.

6. Brush sealer into all exposed seams.

7. Spray the affected area with an approved

service underbody sealer.

8. Remove masking from component mating faces,

and touch-in where necessary. Allow adequate

drying time before applying underbody wax.

Underbody Wax

After refitting mechanical components, including

hoses, pipes and small fixtures, mask off the brake

discs and apply a coat of approved underbody wax.

NOTE: Where repairs include the

application of finish paint coats in the

areas requiring underbody wax, paint

operations must be carried out BEFORE wax

application.

Underbonnet Wax

Where repairs have involved replacement of engine

bay panels, treat the entire engine compartment

including all components, clips and small fixtures with

an approved underbonnet lacquer or wax.

Proprietary Anti-Corrosion Treatments

The application of proprietary anti-corrosion

treatments in addition to the factory-applied treatment

could invalidate the Corrosion Warranty and should be

discouraged. This does not apply to approved,

compatible, preservative waxes which may be applied

on top of existing coatings.

PANEL REPAIRS NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

Fitting Approved Accessories

When fitting accessories it is important that the

vehicle’s corrosion protection is not affected, either by

breaking the protective coating or by introducing a

moisture trap.

DO NOT screw self-tapping screws directly into the

body panel but fit plastic inserts first. Protect the

edges of holes drilled into panels, chassis members

and other body parts with a suitable zinc rich or acid

etch primer, followed by a protective wax coating

brushed onto the surrounding area.

DO NOT affix unpainted metal surfaces of any

accessory directly to the vehicle bodywork unless they

are suitably protected. Where metal faces are bolted

together always interpose a suitable interface material

such as weldable zinc rich primer, extruded strip or

zinc tape.

Cavity Wax Injection

Box sections treated with cavity wax are shown in this

section. Repairs affecting these areas must include

re-treatment with an approved cavity wax, using the

access points ilustrated. In addition, all interior

surfaces which have been disturbed during repairs

must be wax injected whether they have been treated

in production or not. This includes all box members,

cavities, door interiors etc. It is permissible to drill

extra holes for access where necessary, provided

these are not positioned in load-bearing members.

Ensure that such holes are treated with a suitable zinc

rich primer, brushed with wax and then sealed with a

rubber grommet.

Prior to wax injection, ensure that the cavity to be

treated is free from any contamination or foreign

matter. Where necessary, clear out any debris using a

compressed air supply.

Carry out wax injection after final paint operations.

During application, ensure that the wax covers all

flange and seam areas and that it is applied to all

repaired areas of both new and existing panels.

NOTE: Apply cavity wax AFTER the final

paint process and BEFORE refitting of any

trim components.

It should also be noted that new panel assemblies and

body shells are supplied without wax injection

treatment which must be carried out after repairs.

Effective cavity wax protection is vital. Always observe

the following points:

• Complete all finish paint operations before

wax application.

• Clean body panel areas and blow-clean

cavities if necessary, before treatment.

• Maintain a temperature of 18˚ C during

application and drying.

• Check the spray pattern of injection

equipment.

• Mask off all areas not to be wax coated

and which could be contaminated by wax

overspray.

• Remove body fixings, such as seat belt

retractors, if contamination is at all likely.

• Move door glasses to fully closed position

before treating door interiors.

• Treat body areas normally covered by trim

before refitting items.

• Check that body and door drain holes are

clear after the protective wax has dried.

• Keep all equipment clean, especially wax

injection nozzles.

PANEL REPAIRS

SEALING AND CORROSION PROTECTION

Application Equipment and Techniques

1. Air inlet

2. Flow control (spray pattern adjustment)

3. Pressure cup (1 litre [1.7pt.] capacity). Maximum

pressure 140PSI (9.7 bar, 9.8kg/cm

4. Gun connector

5. Lance nipple connection

6. Flexible lance

7. Rigid directional hook wand (forward cone spray

pattern)

8. Flexible nylon 1100mm (43.3in.) lance with 360˚

spray pattern

9. Rigid 1100mm (43.3in.) lance with 360˚ spray

pattern

When re-treating wax-injected areas which have been

disturbed during repairs, it is necessary to use a

compressed air spray gun with integral pressure cup

and a selection of interchangeable lances.

The following points must be observed during use,

according to the attachments fitted:

• Use the rigid or flexible lance attachments

with 360˚ spray dispersal when treating

enclosed areas, to ensure maximum

coverage.

• Where openings are restricted, use the

hook nozzle to provide a more directional

spray (e.g. inside narrow or short box

sections).

• Spray exposed underbody surfaces directly

from the gun less lance attachment and

without disconnecting the fluid coupling.

1100 mm (43.3in.) Rigid Lance:The nozzle on the

rigid lance produces a 360˚ circular spray pattern

combined with a forward-directed spray. Although wax

is distributed to all box section surfaces in a single

stroke, effective and complete coverage is best

achieved in long, straight structures and box section

cavities by spraying on both outbound and return

strokes of the lance.

The rigid lance also provides the positional accuracy

required in shaped sections, by allowing visual

assessment.

CAUTION: Do not force the lance into

access holes when using this attachment.

1100 mm (43.3in.) Flexible Nylon Lance:This lance

is similar in pattern to the rigid version, but provides

the additional penetration needed for curved sections

or in places where access is difficult. Its main

limitation is a lack of positional accuracy inside box

sections.

Carry out spraying on the outward stroke of the lance.

Withdraw the lance slowly to ensure sufficient

coverage. DO NOT withdraw the lance too quickly.

Keep the nylon tube of the lance away from the edges

of the access hole to eliminate abrasion and extend

the life of the tube. Take care to ensure that spraying

ceases just before the nozzle emerges from the

access hole. To assist this process, apply RED paint

to the final 30mm (1.2in.) of the nozzle.

PANEL REPAIRS NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

Hook Nozzle on Flexible Lance:The rigid hook

produces a highly atomised, forward-directed, fully

conical spray pattern having long range and good

dispersion characteristics. This combination has good

directional capabilities for the treatment of short,

narrow sections and may also be used for direct

spraying of inner wheelarches etc.

Position the flat area at the end of the lance at 180˚ to

the nozzle spray direction. This will help to guide the

spray more accurately when it is concealed in a box

section or access hole.

For general spraying move the nozzle in an arc from

side to side, to ensure full coverage.

NOTE: Keep all wax injection/application

equipment clean. Use white spirit for this

purpose immediately after wax injection

operations.

Precautions during Body Repairs and Handling

Take care when handling the vehicle in the workshop.

PVC underbody sealers, seam sealers, underbody

wax and body panels may be damaged if the vehicle

is carelessly lifted.

Always follow the correct lifting, jacking and towing

procedures as shown in GENERAL INFORMATION

DATA, Information section, paying particular

attention to the following points:

• Locate trolley jack pads properly before

lifting and lower the jack fully before

withdrawal.

• Use only the approved hoisting points

when overhead hoisting is required.

• Locate the lifting heads of wheel-free lifts

correctly, with rubber or similar material

placed between lifting head and

underbody.

Steam Cleaning and Dewaxing

Due to the high temperatures generated by steam

cleaning equipment, there is a risk that certain trim

items could be damaged and some adhesives and

corrosion prevention materials softened or liquified.

Adjust the equipment so that the nozzle temperature

does not exceed 90˚ C (194˚ F). Take care not to

allow the steam jet to dwell on one area, and keep the

nozzle at least 300mm (11.8in.) from panel surfaces.

Do NOT remove wax or lacquer from underbody or

underbonnet areas during repairs. Should it be

necessary to steam clean these areas, apply a new

coating of wax or underbody protection as soon as

possible.

PANEL REPAIRS

SEALING AND CORROSION PROTECTION

CAVITY WAX

1. Injection hole at lower ’A’ post.

2. Injection hole at lower ’B’ post.

All areas symmetrically opposite to those shown are also treated.

See GENERAL INFORMATION DATA, Information section.

PANEL REPAIRS NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

SEALANTS AND ADHESIVES

Structural Adhesive

Metal-to-metal adhesive is applied to critical joint

areas during factory assembly. The material used is a

high-temperature, heat cured, nitrile phenolic which

serves both to bond two metal surfaces and also to

seal the joint against ingress of dust, water, petrol and

fumes. This material is not suited for service use, and

should be substituted in repair using a suitable

medium strength adhesive.

When separating a joint treated with metal-to-metal

adhesive, to avoid distortion it is recommended that

the joint be gently heated until the bonds weakens

sufficiently to permit panel separation.

NOTE: Spot welding through

metal-to-metal adhesive is feasible, but

take special care to adjust the transformer

setting to ensure a reliable weld. DO NOT carry

out MIG welding on a joint area which has been

treated with metal-to-metal adhesive until all

traces of adhesive have been removed.

Seam Sealers

A heat cured, PVC Plastisol sealer is applied to joint

areas during factory assembly. This material is not

suitable for service use.

Carry out seam sealing after the application of primer

and before the surfacer and final paint coats. Ensure

that surfaces are first cleaned of all grease and oil.

Apply the sealer material to the joint as a bead, either

by hand or using an applicator gun. Brush sealer well

into the joint and wipe smooth using a cloth soaked

with solvent such as Shell SBP3. This will ensure an

acceptable cosmetic finish.

Apply sealer to ALL accessible joints following repair

work. Be aware that damage to a vehicle can often

result in deflection to those areas of the body which

are remote from the impact. The sealers in these

areas can therefore be disturbed by subsequent

straightening and repair operations. Check joints in

the vicinity of the area undergoing repair for evidence

of cracked sealer, clean them out as required and

re-treat them with fresh sealer using the following

procedure:

• Clean the affected joint or seam and

re-treat any exposed metal areas with a

suitable etch phosphate primer.

• Treat affected area with an acid-etch

primer.

• Apply appropriate seam sealer as

necessary.

• Apply appropriate colour coat (and

underbody sealer as applicable).

Where joints are inaccessible following the

reassembly or fitment of components, ensure that a

paste-type sealer is applied to such joints. Certain

seams also become inaccessible after the completion

of panel repairs. In such instances the paint process

should be carried out and sealers applied before final

assembly.

Provided access is adequate, apply the sealer to both

sides of the repair joint. Where access is limited to

one side only (e.g. box sections), inject the affected

box member with cavity wax.

CAUTION: ALWAYS deploy an extractor

unit to remove toxic fumes when using

oxy-acetylene equipment to remove panels

treated with wax and sealers.

PANEL REPAIRS

SEALING AND CORROSION PROTECTION

Sealing Water Leaks

Sealing charts in this section show those areas of the

bodyshell most likely to be affected by accident

damage and water leaks, and which could therefore

require re-treatment in repair. They do not show those

joint areas which only apply to factory assembly

operations and which are unlikely to be disturbed in

service (e.g. centre tunnel), or where the damage

would be so severe that the entire bodyshell would

normally be written off.

When water leakage occurs, always adopt a logical

approach to the problem using a combination of skill,

experience and intuition. Do not attempt to reach a

conclusion based only on visual evidence, such as

assuming that a leak emanates from the windscreen

because the footwell is wet. It will often be found that

the source of the leak is elsewhere. The correct

procedure will increase the chance of locating a leak,

however obscure it may seem.

Tools and Equipment

The following tools and equipment are recommended

for detection and rectification of water leaks:

1. Garden sprayer (hand-operated).

2. Wet/dry vacuum cleaner.

3. Dry absorbent cloths.

4. Battery torch.

5. Small mirror.

6. Weatherstrip locating tool.

7. Trim panel remover.

8. Small wooden or plastic wedges.

9. Dry compressed air supply.

10. Hot air blower.

11. Sealer applicators.

12. Ultrasonic leak detector.

During leak detection, the vehicle should be

considered in three basic sections:

• The front interior space,

• The rear passenger space (where

applicable), and

• The rear loadspace or boot.

Testing

From the information supplied by the customer it

should be possible for the bodyshop operator to locate

the starting point from which the leak may be

detected. After the area of the leak has been

identified, find the actual point of entry into the vehicle.

A simple and effective means initially is an ordinary

garden spray with provision for pressure and jet

adjustment. This will allow water to be directed in a jet

or turned into a fine spray. Use a mirror and a

battery-powered torch (NOT a mains voltage

inspection lamp) to see into dark corners.

The sequence of testing is particularly important. Start

at the lowest point and work slowly upwards, to avoid

testing in one area while masking the leak in another.

For example, if testing started at the level of the

windscreen, any water cascading into the plenum

chamber could leak through a bulkhead grommet and

into the footwells. Even at this point it could still be

wrongly assumed that the windscreen seal was at

fault.

Another important part of identifying a water leak is by

visual examination of door aperture seals, grommets

and weatherstrips for damage, deterioration or

misalignment, together with the fit of the door itself

against the seals.

PANEL REPAIRS NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

Sealing

When the point of the leak has been detected,

proceed to rectify it using the following procedure:

1. Renew all door aperture seals and weatherstrips

which have suffered damage, misalignment or

deterioration.

2. Check all body seals to ensure that they are

correctly located on their mounting flanges/faces

using a locating tool if necessary.

3. Dry out body seams to be treated using

compressed air and/or a hot air blower as

necessary.

4. Apply sealant on the outside of the joint

wherever possible to ensure the exclusion of

water.

5. When rectifying leaks between a screen glass

and its weatherstrip (or in the case of direct

glazing, between the glass and bodywork), avoid

removing the glass if possible. Apply the

approved material either at the glass to

weatherstrip or glass to body.

PANEL REPAIRS

SEALING AND CORROSION PROTECTION

SEALING CHARTS

1. Structural adhesive

2. Structural adhesive

3. Structural adhesive

4. Structural adhesive

5. Structural adhesive, seam sealer

6. Structural adhesive, seam sealer

7. Semi-structural adhesive/anti-flutter material

8. Semi-structural adhesive/anti-flutter material

9. Semi-structural adhesive/anti-flutter material

10. Semi-structural adhesive/anti-flutter material

11. Structural adhesive

12. Structural adhesive

All areas symmetrically opposite to those shown are also treated.

see GENERAL INFORMATION DATA, Information section.

PANEL REPAIRS NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

13. Putty

14. Putty

15. Structural adhesive

16. Putty, seam sealer heavy

17. Putty, seam sealer heavy

18. Structural adhesive

19. Structural adhesive

20. Structural adhesive

21. Structural adhesive

All areas symmetrically opposite to those shown are also treated.

See GENERAL INFORMATION DATA, Information section.

PANEL REPAIRS

SEALING AND CORROSION PROTECTION

22. Structural adhesive

23. Semi-structural adhesive/anti-flutter material

24. Seam sealer light

25. Seam sealer light, structural adhesive

26. Seam sealer light

27. Seam sealer

28. Seam sealer

29. Seam sealer heavy

30. Seam sealer light

31. Seam sealer light

All areas symmetrically opposite to those shown are also treated.

See GENERAL INFORMATION DATA, Information section.

PANEL REPAIRS NEW RANGE ROVER

SEALING AND CORROSION PROTECTION

34. Seam sealer light

35. Seam sealer light

36. Seam sealer light

37. Seam sealer light

All areas symmetrically opposite to those shown are also treated.

See GENERAL INFORMATION DATA, Information section.

PANEL REPAIRS

SEALING AND CORROSION PROTECTION

32. Brushable sealer

33. Seam sealer light

38. Seam sealer light

39. Seam sealer light

40. Seam sealer light

41. Seam sealer light

All areas symmetrically opposite to those shown are also treated.

See GENERAL INFORMATION DATA, Information section.

PANEL REPAIRS

PANELS

PAINT

Replacement Panels

Service panels are supplied with a cathodic primer

coating as part of the panel protection, and in

compliance with the vehicle’s Corrosion Warranty

where applicable. DO NOT remove this primer

before paint refinishing. In the event of localised

surface damage or imperfections, ensure that the

minimum of primer is removed during rectification

work for effective repair.

Rectify damage by panel beating or straightening. To

remove corrosion or paint runs on outer surfaces,

abrade primer coat in the affected area as necessary

using the following procedure:

1. Clean the panel using a solvent wipe.

2. Treat exposed areas of metal with an etch

phosphate process.

3. Re-treat the affected area using either a

separate acid-etch primer and two-pack

surfacer, or an integrated etch primer/filler.

Bolted Panels

Before fitting bolt-on panels, ensure that all mating

and adjacent surfaces on the vehicle and replacement

panel are free from damage and distortion. Rectify if

necessary as described in this section, and apply

preformed strip sealer where specified.

Welded Panels

1. Remove primer from the immediate vicinity of

new and existing panel flanges, cleaning to

bright metal finish.

2. On joints to be spot welded, apply weld-through

zinc rich primer to joint faces of both flanges.

Make spot welds while primer is still wet or

according to the manufacturer’s instructions.

3. Dress accessible weld seams.

4. Clean panel using solvent wipe.

5. Treat bare metal with an etch phosphate

process.

6. Re-treat repaired areas.

NOTE: It is not satisfactory to use

weld-through, zinc rich primers in

conjunction with arc or MIG welding.

Sectioned Panels

When replacing part or sectioned panels, the basic

procedure is the same as for welded panels described

above, with the following variations:

1. Remove primer from both new and existing joint

faces, cleaning to a bright metal finish.

2. Where an overlap joint with the existing panel is

to be spot welded, apply weld-through, zinc rich

primer to both joint faces and spot weld while the

primer is still wet or according to the

manufacturer’s instructions.

3. MIG weld butt joints where applicable.

4. Clean the panel with a solvent wipe.

5. Treat bare metal areas using an etch phosphate

process.

6. Re-prime affected areas as necessary as for

rectifying transit damage. See this section.

7. Treat the inner faces of lap or butt joints with a

suitable cavity wax. See Sealing and corrosion

protection.

PANEL REPAIRS NEW RANGE ROVER

PANELS

Clinch Panels (eg Doorskins etc.)

1. Abrade primer on new and existing panel joint

faces, and clean using a solvent wipe.

2. Apply metal-to-metal adhesive where applicable.

3. Where joints are to be spot welded, apply

suitable weld-through, zinc rich primer to weld

areas.

4. Where joints are to be MIG, arc or gas welded,

apply zinc rich primer in adjacent areas but

leave the welded area untreated.

5. To retain the panel whilst clinching the flanges,

tack spot weld or plug weld as appropriate.

6. Clean the panel with a solvent wipe.

7. Treat bare metal areas with a suitable etch

phosphate process.

8. Re-prime affected areas as necessary as for

rectifying transit damage. See this section.

NOTE: Replacement doors, bonnets and

tailgates must be treated with a suitable

seam sealer on clinched seams, following

the primer coat.

Paint Refinishing

1. Seal all accessible exterior and interior seams

with an approved seam sealer. Certain joints

such as sill lower flange seams must be left

unsealed.

2. Apply a suitable anti-chip primer where

specified.

3. Apply a two-pack paint refinishing system.

4. Repair any damage to underbody sealers either

at this stage or before paint operations.

Paint Repairs

Before carrying out paintwork repairs, the vehicle

must be thoroughly cleaned using either a steam

cleaner or high-pressure washer.

Wash locally repaired areas using a mild

water-mixable detergent and wipe them clean with

solvent, immediately prior to paint application.

Abrade damaged paintwork where bare metal has

been exposed until the metal is clean and extends

beyond the area of immediate damage. Treat the bare

metal with an etch phosphate to remove all traces of

rust and provide a key for new paint coats. Re-treat

the affected area using either a separate acid-etch

primer and two-pack surfacer or an integrated etch

primer/filler, and follow with a two-pack paint system.

Those surfaces not receiving paint must be treated

with a cavity wax following paint operations.

A. Two-pack top coat

B. Two-pack primer filler and etch primer

C. Etch phosphate

PANEL REPAIRS

PANELS

SERVICE CONDITION OF PANELS

Bodyshell Assembly

Bodyshells, which are also supplied with sunroof

aperture (not shown), are serviced less front wings,

bonnet,door assemblies and upper/lower tailgates.

Headlamp and Grille Panel

Headlamp/grille panels are serviced as a complete

assembly including a bolt-on bonnet lock platform.

Front Wing

Front wings are serviced as separate bolt-on

aluminium panels.

Bonnet

Bonnets are serviced less hinges which are available

separately.

PANEL REPAIRS NEW RANGE ROVER

PANELS

Valance and Wheelarch

Valance and wheelarch panels are serviced as a

separate part and are fitted to the bulkhead.

Front Sidemember

Front sidemembers are fitted to the ’A’ post and

valance/wheelarch.

’A’ Post Lower

The ’A’ post lower is fitted to the bulkhead, inner sill

and ’A’ post reinforcement.

’A’ Post Panels

’A’ posts are serviced as separate ’A’ post repair

panel (1), upper ’A’ post (2) and ’A’ post reinforcement

(3).

’B’ Post Panels

’B’ posts are serviced as separate ’BC’ post

reinforcement (1) and inner ’BC’ post panels (2, 3).

PANEL REPAIRS

PANELS

Door Assemblies and Outer Door Panels

Door assemblies comprise an aluminium outer panel

fitted to a steel frame.

’BC’ Post Repair Panel

’BC’ posts are serviced as a complete panel including

the sill.

Roof Assembly

Roof assemblies are serviced complete with inner

frames.

PANEL REPAIRS NEW RANGE ROVER

PANELS

Outer Rear Quarter Panel

Outer rear quarters are serviced as a separate panel.

Lower Panel

Lower panels are serviced as an assembly including

the tailgate lock reinforcement.

Upper Tailgate Assembly

Upper tailgates are serviced less hinges, which are

available separately.

Lower Tailgate Assembly

Lower tailgate assemblies comprise an aluminium

outer panel fitted to a steel frame and are serviced

less hinges, which are available separately. Lower

tailgate outer panels are also serviced as separate

items.

PANEL REPAIRS

PANELS

Inner Rear Quarter Panel

Inner rear quarters are serviced as an assembly with

associated reinforcements and brackets.

Rear Crossmember Panel

The rear crossmember is serviced as a separate

panel.

Load Floor Side

Load floor sides are serviced as a separate panel.

Rear Crossmember Extension

The rear crossmember extension is serviced

separately.

PANEL REPAIRS NEW RANGE ROVER

PANELS

Rear Quarter Repair Panel

The rear quarter which is fitted between the outer

panel and inner quarter is serviced as a separate

repair panel.

Spare Wheel Closing Panel

The spare wheel closing panel is serviced separately

and fits at the upper front of the spare wheel well.

PANEL REPAIRS

PROCEDURES

GENERAL WELDING PRECAUTIONS

For ease of reference the diagrams on the following

pages show only the type of weld used in repair where

this varies from that used in production.

When carrying out welding operations the following

criteria must be observed:

• Where resistance spot welds have been

used in production, these must be

reproduced with new spot welds in

replacement where possible. All such

reproduction spot welds must be spaced

30mm (1.2in.) apart.

• When spot welding, it is recommended that

test coupons of the same metal gauges

and materials are produced to carry out

peel tests to ensure that welding

equipment being used can produce a

satisfactory joint. Plug welds must be used

if a satisfactory spot weld cannot be

produced.

• The electrode arms on hand-held spot

welding guns must not exceed 300mm in

length.

• Single-sided spot welding is not

acceptable.

• Brazing and gas welding are not

acceptable EXCEPT where they have been

specified in production.

• Where 3 metal thicknesses or more are to

be welded together it is imperative to use

MIG plug welds to ensure joint strength.

• MIG plug welds must be used in repair

joints where there is no access for a

resistance spot welder. To replace each

production spot weld a hole must be drilled

and/or punched, and a MIG weld then

made in its place. The number of plug

welds must match exactly the number of

spot welds which have been removed.

• Where holes are left in an existing panel

after removal of the spot welds, a single

MIG plug weld will be made in each hole as

appropriate.

• The replacement welds in the welding

diagrams are denoted by the following

symbols:

A. Single thickness plug welds

B. Multiple thickness plug welds

C. MIG seam weld

Seat Belt Anchorages

Seat belt anchorages are safety critical. When making

repairs in these areas it is essential to follow design

specifications. Note that High Strength Low Alloy

(HSLA) steel may be used for seat belt anchorages.

Where possible, the original production assembly

should be used, complete with its seat belt

anchorages, or the cut line should be so arranged that

the original seatbelt anchorage is not disturbed.

All welds within 250mm (9.9in.) of seat belt

anchorages must be carefully checked for weld

quality, including spacing of spot welds.

WARNING: Body parts incorporating seat

belt anchorages MUST be renewed

completely if damaged beyond repair, as

the welds in these areas are safety critical and

cannot be disturbed.

PANEL REPAIRS NEW RANGE ROVER

PROCEDURES

PANEL REPLACEMENT PROCEDURE

General

This information is designed to explain the basic panel

removal and replacement method. This standard

method may vary slightly from one vehicle to another.

The main criterion in removal and replacement of

body panels is that Land Rover’s original standard is

maintained as far as possible.

Remove Panel

1. Expose resistance spot welds. For those spot

welds which are not obviously visible, use a

rotary impregnated wire brush fitted to an air

drill, or alternatively a hand held wire brush.

NOTE: In wheelarch areas it may be

necessary to soften underbody coating

using a hot air gun, prior to exposing spot

welds.

2. Cut out welds using a cobalt drill.

3. Alternatively use a clamp-type spot weld

remover.

PANEL REPAIRS

PROCEDURES

4. Cut away the bulk of the panel as necessary

using an air saw.

NOTE: On certain panel joints MIG welds

and braze should be removed using a

sander where possible, before cutting out

the panel bulk.

5. Separate spot welded joints and remove panel

remnants using hammer, bolster chisel and

pincers.

Prepare Old Surfaces

6. Clean all panel joint edges to a bright smooth

finish, using a belt-type sander.

NOTE: Prior to sanding, remove remaining

sealant using a hot air gun to minimise the

risk of toxic fumes caused by generated

heat. CARE MUST BE TAKEN TO AVOID

EXCESSIVE HEAT BUILD UP WHICH MAY BE

CAUSED BY THIS EQUIPMENT.

7. As an alternative a disc sander may be used.

Straighten existing joint edges using shaping

block and hammer.

PANEL REPAIRS NEW RANGE ROVER

PROCEDURES

Prepare New Surfaces

8. Mark out bulk of new panel and trim to size,

leaving approximately 50mm (1.9in.) overlap

with existing panel. Offer up new panel/section,

align with associated panels (e.g. new rear

quarter aligned with door and tailgate). Clamp

into position.

9. Cut new and existing panels as necessary to

form butt, joggle or brace joint as required.

Remove all clamps and metal remnants.

10. Prepare new panel joint edges for welding by

sanding to a bright finish. This must include inner

as well as outer faces.

11. Apply suitable weld-through primer to panel joint

surfaces to be welded, using brush or aerosol

can.

PANEL REPAIRS

PROCEDURES

12. Apply adhesive sealant to panel joint surfaces.

See GENERAL SPECIFICATION DATA,

Information section.

Offer Up and Align

Offer up new panel and align with associated panels.

Clamp into position using welding clamps or Mole

grips. Where a joggle or brace joint is being adopted,

make a set in the original panel joint edge or insert a

brace behind the joint.

NOTE: In cases where access for welding

clamps is difficult, it may be necessary to

use tack welds.

Welding

13. Select arms for resistance spot welding and

shape electrode tips using a tip trimmer.

NOTE: To maintain efficiency, the tips will

require regular cleaning with emery cloth.

CAUTION: Use electrode arms not

exceeding 300mm (11.8in.) in length.

14. Fit resistance spot welding arms and test

equipment for satisfactory operation, using test

coupons. Where monitoring equipment is not

available, verify weld strength by checking that

metal around the weld puddle pulls apart under

tension during pulling.

PANEL REPAIRS NEW RANGE ROVER

PROCEDURES

15. Use a resistance spot welder where access

permits. Try to ensure weld quality by using a

weld monitor where possible.

16. MIG tack weld butt joints and re-check alignment

and panel contours where necessary. Ensure

that a gap is maintained to minimise welding

distortion, by inserting a hacksaw blade as an

approximate guide.

17. Dress MIG tack welds using a sander with 36 grit

disc, or a belt-type sander where access is

limited.

PANEL REPAIRS

PROCEDURES

18. MIG seam weld butt joints.

19. Always use MIG plug welds where excessive

metal thickness or lack of access make

resistance spot welding impractical. Make plug

welds either by using holes left by the spot weld

cutter, or through holes punched or drilled for the

purpose.

20. Dress all welds using a sander with 36 grit disc,

or a belt-type sander and/or impregnated wire

brush.

NOTE: Brazing operations, if required,

must be carried out at this point.

Body Trim

The following panel repair operations itemise body

trim components which must be removed for access

during each repair. See Repairs section.

Because of the unpredictable nature of accident

damage, the items listed make no allowance for any

difficulties which may be found in removal and only

apply to an undamaged vehicle. No allowance is

made for any difficulties which may be found during

panel removal. Damaged body trim items must be

renewed as necessary following body repairs.

PANEL REPAIRS

REPAIR

VALANCE AND WHEELARCH

Remove

1. Disconnect battery earth lead.

2. Raise front of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Remove airbag modules.

See

SUPPLEMENTARY RESTRAINT SYSTEM,

Repair.

6. Disconnect alternator.

7. Remove front bumper valance.

See CHASSIS

AND BODY, Repair.

8. Remove extension spoiler front bumper.

See

CHASSIS AND BODY, Repair.

9. Remove front grille.

See CHASSIS AND BODY,

Repair.

10. Remove headlamp.

See Workshop Manual -

ELECTRICAL.

11. Remove bonnet.

See CHASSIS AND BODY,

Repair.

12. Remove bonnet strut.

See CHASSIS AND

BODY, Repair.

13. Remove bonnet lock RH or LH.

See CHASSIS

AND BODY, Repair.

14. Remove wheel arch liner - front.

See CHASSIS

AND BODY, Repair.

15. Remove front door assembly.

See CHASSIS

AND BODY, Repair.

16. Remove ’A’ post trim.

See CHASSIS AND

BODY, Repair.

17. Remove fascia.

See CHASSIS AND BODY,

Repair.

18. Remove front wing.

19. Remove engine.

See Workshop Manual -

ENGINE.

20. Remove gearbox.

See Workshop Manual -

GEARBOX.

Refit

NOTE: In this operation the valance and

wheelarch is fitted in combination with a

front sidemember.

21. Prepare and clean panel joint faces. Punch or

drill holes in new valance and wheelarch for plug

welding as shown.

22. Reverse removal procedure.

23. Remove stands and lower vehicle.

PANEL REPAIRS NEW RANGE ROVER

REPAIR

FRONT SIDEMEMBER

Remove

1. Disconnect battery earth lead.

2. Raise front of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Remove airbag module.

See

SUPPLEMENTARY RESTRAINT SYSTEM,

Repair.

6. Disconnect alternator.

7. Remove front bumper valance.

See CHASSIS

AND BODY, Repair.

8. Remove extension spoiler front bumper.

See

CHASSIS AND BODY, Repair.

9. Remove front grille.

See CHASSIS AND BODY,

Repair.

10. Remove headlamp.

See Workshop Manual -

ELECTRICAL

11. Remove bonnet.

See CHASSIS AND BODY,

Repair.

12. Remove bonnet strut.

See CHASSIS AND

BODY, Repair.

13. Remove bonnet lock RH or LH.

See CHASSIS

AND BODY, Repair.

14. Remove wheel arch liner - Front.

See CHASSIS

AND BODY, Repair.

15. Remove front door assembly.

See CHASSIS

AND BODY, Repair.

16. Remove ’A’ post trim.

See CHASSIS AND

BODY, Repair.

17. Remove front wing.

Refit

18. Prepare and clean panel joint faces. Punch or

drill holes in new front sidemember for plug

welding as shown.

WARNING: Remove ALL traces of

adhesive from valance upper edge before

plug welding.

19. Reverse removal procedure.

20. Remove stands and lower vehicle.

PANEL REPAIRS

REPAIR

UPPER ’A’ POST PANEL AND REPAIR PANEL

Remove

1. Disconnect battery earth lead.

2. Raise front of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Remove both airbag modules.

See

SUPPLEMENTARY RESTRAINT SYSTEM,

Repair. See SUPPLEMENTARY RESTRAINT

SYSTEM, Repair.

6. Disconnect alternator.

7. Remove front bumper valance.

See CHASSIS

AND BODY, Repair.

8. Remove extension spoiler front bumper.

See

CHASSIS AND BODY, Repair.

9. Remove front grille.

See CHASSIS AND BODY,

Repair.

10. Remove windscreen.

See CHASSIS AND

BODY, Repair.

11. Remove headlamp.

See Workshop Manual -

ELECTRICAL.

12. Remove bonnet.

See CHASSIS AND BODY,

Repair.

13. Remove wheel arch liner - front.

See CHASSIS

AND BODY, Repair.

14. Remove front door assembly.

See CHASSIS

AND BODY, Repair.

15. Remove ’A’ post trim.

See CHASSIS AND

BODY, Repair.

16. Remove fascia assembly.

See CHASSIS AND

BODY, Repair.

17. Remove front wing.

Refit

NOTE: In this operation, the ’A’ post panel

and repair panel are replaced in

combination with the lower ’A’ post and

reinforcement. It is also necessary to remove the

front sidemember for access.

18. Prepare and clean panel joint faces. Punch or

drill holes in new panels for plug welding as

shown.

WARNING: Remove ALL traces of

adhesive from outer face of ’A’ post

reinforcement before plug welding.

Cut upper ’A’ post and repair panel to form seam

welded joints with existing panels.

19. Reverse removal procedure.

20. Remove stands and lower vehicle.

PANEL REPAIRS NEW RANGE ROVER

REPAIR

LOWER ’A’ POST AND REINFORCEMENT

Remove

1. Disconnect battery earth lead.

2. Raise front of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Remove both airbag modules.

See

SUPPLEMENTARY RESTRAINT SYSTEM,

Repair. See SUPPLEMENTARY RESTRAINT

SYSTEM, Repair.

6. Disconnect alternator.

7. Remove front bumper valance.

See CHASSIS

AND BODY, Repair.

8. Remove extension spoiler front bumper.

See

CHASSIS AND BODY, Repair.

9. Remove front grille.

See CHASSIS AND BODY,

Repair.

10. Remove windscreen.

See CHASSIS AND

BODY, Repair.

11. Remove headlamp.

See Workshop Manual -

ELECTRICAL.

12. Remove bonnet.

See CHASSIS AND BODY,

Repair.

13. Remove wheel arch liner - front.

See CHASSIS

AND BODY, Repair.

14. Remove front door assembly.

See CHASSIS

AND BODY, Repair.

15. Remove ’A’ post trim.

See CHASSIS AND

BODY, Repair.

16. Remove fascia assembly.

See CHASSIS AND

BODY, Repair.

17. Remove front wing.

Refit

NOTE: In this operation, the lower ’A’ post

and reinforcement are replaced in

combination with the upper ’A’ post and

repair panel. It is also necessary to remove the

front sidemember for access.

18. Prepare and clean panel joint faces. Punch or

drill holes in new panels for plug welding as

shown.

WARNING: Remove ALL traces of

structural adhesive from dash

reinforcement end flange before plug

welding.

Cut ’A’ post reinforcement to form a seam welded butt

joint with existing panel.

19. Reverse removal procedure.

20. Remove stands and lower vehicle.

PANEL REPAIRS

REPAIR

’BC’ POST REPAIR PANEL

Remove

1. Disconnect battery earth lead.

2. Raise side of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Remove both airbag modules.

See

SUPPLEMENTARY RESTRAINT SYSTEM,

Repair. See SUPPLEMENTARY RESTRAINT

SYSTEM, Repair.

6. Disconnect alternator.

7. Remove front seat.

See CHASSIS AND BODY,

Repair.

8. Remove seat belt - front.

See CHASSIS AND

BODY, Repair.

9. Remove front seat belt adjustable mounting.

See CHASSIS AND BODY, Repair.

10. Remove B post trim.

See CHASSIS AND

BODY, Repair.

11. Remove rear door assembly.

See CHASSIS

AND BODY, Repair.

Refit

12. Prepare and clean panel joint faces. Punch or

drill holes in new ’BC’ post repair panel for plug

welding as shown. Cut panel to form seam

welded butt joints with existing panel.

13. Reverse removal procedure.

14. Remove stands and lower vehicle.

PANEL REPAIRS NEW RANGE ROVER

REPAIR

’BC’ POST REINFORCEMENT

Remove

1. Disconnect battery earth lead.

2. Raise side of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Disconnect alternator.

6. Remove front seat.

See CHASSIS AND BODY,

Repair.

7. Remove seat belt - front.

See CHASSIS AND

BODY, Repair.

8. Remove front seat belt adjustable mounting.

See CHASSIS AND BODY, Repair.

9. Remove B post trim.

See CHASSIS AND

BODY, Repair.

10. Remove rear door assembly.

See CHASSIS

AND BODY, Repair.

Refit

NOTE: In this operation, the ’B’ post

reinforcement and ’B’ post repair panel are

replaced in combination.

11. Prepare and clean panel joint faces. Punch or

drill holes in new panel for plug welding as

shown. Cut new panel to form seam welded butt

joint with existing panel.

12. Reverse removal procedure.

13. Remove stands and lower vehicle.

PANEL REPAIRS

REPAIR

’BC’ POST INNER PANELS

Remove

1. Disconnect battery earth lead.

2. Raise side of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Disconnect alternator.

6. Remove front seat.

See CHASSIS AND BODY,

Repair.

7. Remove seat belt - front.

See CHASSIS AND

BODY, Repair.

8. Remove front seat belt adjustable mounting.

See CHASSIS AND BODY, Repair.

9. Remove ’B’ post trim.

See CHASSIS AND

BODY, Repair.

10. Remove rear door assembly.

See CHASSIS

AND BODY, Repair.

Refit

NOTE: In this operation, the inner panels

are replaced in combination with a ’B’ post

reinforcement and repair panel.

11. Prepare and clean panel joint faces. Punch or

drill holes in new ’BC’ post inner panels for plug

welding as shown.

12. Reverse removal procedure.

13. Remove stands and lower vehicle.

PANEL REPAIRS NEW RANGE ROVER

REPAIR

ROOF ASSEMBLY

Remove

1. Disconnect battery earth lead.

2. Disconnect all ECUs.

3. Disconnect airbags and sensor system.

4. Disconnect alternator.

5. Remove headlining - sliding roof.

See CHASSIS

AND BODY, Repair.

6. Remove sliding roof - electric.

See CHASSIS

AND BODY, Repair.

7. Remove windscreen.

See CHASSIS AND

BODY, Repair.

8. Remove front door assembly.

See CHASSIS

AND BODY, Repair.

9. Remove rear door assembly.

See CHASSIS

AND BODY, Repair.

10. Remove tailgate - upper.

See CHASSIS AND

BODY, Repair.

11. Remove seat belt - front.

See CHASSIS AND

BODY, Repair.

12. Remove front seat belt adjustable mounting.

See CHASSIS AND BODY, Repair.

13. Remove A, B, D and E post trims.

See

CHASSIS AND BODY, Repair.

14. Remove sunroof drain tube - front.

See

CHASSIS AND BODY, Repair.

15. Remove sunroof drain tube - rear.

See

CHASSIS AND BODY, Repair.

Refit

16. Prepare and clean panel joint faces. Punch or

drill holes in new roof assembly for plug welding

as shown.

WARNING: Remove ALL traces of

adhesive from joints to cant rail front and

rear corners before plug welding.

17. Reverse removal procedure.

PANEL REPAIRS

REPAIR

OUTER REAR QUARTER PANEL

Remove

1. Disconnect battery earth lead.

2. Raise rear of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Disconnect alternator.

6. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

7. Remove parcel tray support.

See CHASSIS

AND BODY, Repair.

8. Remove parcel tray support trim.

See CHASSIS

AND BODY, Repair.

9. Remove ’E’ post - exterior trim.

See CHASSIS

AND BODY, Repair.

10. Remove D and E post trims.

See CHASSIS

AND BODY, Repair.

11. Remove wheel arch liner - rear.

See CHASSIS

AND BODY, Repair.

12. Remove rear quarter light.

See CHASSIS AND

BODY, Repair.

13. Remove quarter panel rubbing strips.

See

CHASSIS AND BODY, Repair.

14. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

15. Remove rear seat belt - left hand or right hand.

See CHASSIS AND BODY, Repair. See

CHASSIS AND BODY, Repair.

16. Remove sunroof drain tube - rear.

See

CHASSIS AND BODY, Repair.

Refit

17. Prepare and clean panel joint faces. Punch or

drill holes in new panel for plug welding as

shown. Apply structural adhesive at joint to outer

wheelarch.

See Corrosion protection.

WARNING: Remove ALL traces of

adhesive from joint to lower panel before

plug welding.

18. Reverse removal procedure.

19. Remove stands and lower vehicle.

PANEL REPAIRS NEW RANGE ROVER

REPAIR

INNER REAR QUARTER PANEL

Remove

1. Disconnect battery earth lead.

2. Raise rear of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Disconnect alternator.

6. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

7. Remove tailgate - upper.

See CHASSIS AND

BODY, Repair.

8. Remove parcel tray support and trim.

See

CHASSIS AND BODY, Repair.

9. Remove ’E’ post - exterior trim.

See CHASSIS

AND BODY, Repair.

10. Remove ’D’ and ’E’ post trims.

See CHASSIS

AND BODY, Repair.

11. Remove wheel arch liner - rear.

See CHASSIS

AND BODY, Repair.

12. Remove rear quarterlight.

See CHASSIS AND

BODY, Repair.

13. Remove appropriate rubbing strip.

See

CHASSIS AND BODY, Repair.

14. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

15. Remove rear seat belt - left hand or right hand.

See CHASSIS AND BODY, Repair. See

CHASSIS AND BODY, Repair.

16. Remove sunroof drain tube - rear.

See

CHASSIS AND BODY, Repair.

Refit

NOTE: In this operation, the inner rear

quarter panel, outer quarter and rear

quarter repair panel are replaced in

combination .

17. Prepare and clean panel joint faces. Apply

structural adhesive at joint to floor at lower edge

of wheelarch.

See Corrosion protection.

Plug weld at joints to floor using holes left by spot

weld cutter. Cut inner rear quarter to form seam

welded butt joints with existing panel.

WARNING: Remove ALL traces of

adhesive from joint to floor inside vehicle

before plug welding.

18. Reverse removal procedure.

19. Remove stands and lower vehicle.

PANEL REPAIRS

REPAIR

REAR QUARTER REPAIR PANEL

Remove

1. Disconnect battery earth lead.

2. Raise rear of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Disconnect alternator.

6. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

7. Remove tailgate - upper.

See CHASSIS AND

BODY, Repair.

8. Remove parcel tray support and trim.

See

CHASSIS AND BODY, Repair.

9. Remove ’E’ post - exterior trim.

See CHASSIS

AND BODY, Repair.

10. Remove ’D’ and ’E’ post trims.

See CHASSIS

AND BODY, Repair.

11. Remove wheel arch liner - rear.

See CHASSIS

AND BODY, Repair.

12. Remove rear quarterlight.

See CHASSIS AND

BODY, Repair.

13. Remove rear quarter rubbing strip.

See

CHASSIS AND BODY, Repair.

14. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

15. Remove rear seat belt - left hand or right hand.

See CHASSIS AND BODY, Repair.

16. Remove sunroof drain tube - rear.

See

CHASSIS AND BODY, Repair.

Refit

NOTE: In this operation, the rear quarter

repair panel, outer quarter and rear quarter

repair panel are replaced in combination.

17. Cut new rear quarter repair panel to form MIG

welded butt joints with existing panels.

CAUTION: Do NOT cut into the inner

quarter during this operation.

18. Reverse removal procedure.

19. Remove stands and lower vehicle.

PANEL REPAIRS NEW RANGE ROVER

REPAIR

LOAD FLOOR SIDE

Remove

1. Disconnect battery earth lead.

2. Raise rear of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Disconnect alternator.

6. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

7. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

Refit

8. Prepare and clean panel mating faces. Punch or

drill holes in new rear floor panel for plug welding

as shown. Plug weld also to spare wheel well

edges using holes left by spot weld cutter.

9. Reverse removal procedure.

10. Remove stands and lower vehicle.

REAR CROSSMEMBER PANEL

Remove

1. Disconnect battery earth lead.

2. Raise rear of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Disconnect alternator.

6. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

7. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

Refit

8. Prepare and clean panel joint faces. Punch or

drill holes in new rear crossmember panel for

plug welding as shown.

9. Reverse removal procedure.

10. Remove stands and lower vehicle.

PANEL REPAIRS

REPAIR

REAR FLOOR EXTENSION PANEL

Remove

1. Disconnect battery earth lead.

2. Raise rear of vehicle.

WARNING: Support on safety stands.

3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

5. Disconnect alternator.

6. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

7. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

Refit

8. Prepare and clean panel joint faces. Punch or

drill holes in new rear crossmember extension

panel for plug welding as shown.

9. Reverse removal procedure.

10. Remove stands and lower vehicle.

SPARE WHEEL CLOSING PANEL

Remove

1. Disconnect battery earth lead.

2. Disconnect all ECUs.

3. Disconnect airbags and sensor system.

4. Disconnect alternator.

5. Remove rear seat belt - left hand.

See

CHASSIS AND BODY, Repair.

6. Remove rear seat belt - right hand.

See

CHASSIS AND BODY, Repair.

7. Remove rear seatbelt - centre.

See CHASSIS

AND BODY, Repair.

Refit

8. Prepare and clean panel joint faces. Punch or

drill holes in new spare wheel closing panel for

plug welding as shown.

9. Reverse removal procedure.

PANEL REPAIRS NEW RANGE ROVER

REPAIR

LOWER PANEL

Remove

1. Disconnect battery earth lead.

2. Disconnect all ECUs.

3. Disconnect airbags and sensor system.

4. Disconnect alternator.

5. Remove tailgate - lower.

See CHASSIS AND

BODY, Repair.

6. Remove tailgate striker.

See CHASSIS AND

BODY, Repair.

7. Remove rear bumper valance.

See CHASSIS

AND BODY, Repair.

Refit

8. Prepare and clean panel joint faces. Punch or

drill holes in new lower panel for plug welding as

shown.

WARNING: remove ALL traces of adhesive

from joints to quarter panels before plug

welding.

9. Reverse removal procedure.